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Research Papers: Gas Turbines: Manufacturing, Materials, and Metallurgy

Optimization of a Centrifugal Compressor Impeller for Robustness to Manufacturing Uncertainties

[+] Author and Article Information
A. Javed

Faculty of Mechanical,
Maritime and Materials Engineering,
Delft University of Technology,
Process and Energy Laboratory,
Leeghwaterstraat 39,
Delft 2628 CB, The Netherlands
e-mail: adeel.javed@epfl.ch

R. Pecnik

Faculty of Mechanical,
Maritime and Materials Engineering,
Delft University of Technology,
Process and Energy Laboratory,
Leeghwaterstraat 39,
Delft 2628 CB, The Netherlands
e-mail: r.pecnik@tudelft.nl

J. P. van Buijtenen

Faculty of Mechanical,
Maritime and Materials Engineering,
Delft University of Technology,
Process and Energy Laboratory,
Leeghwaterstraat 39,
Delft 2628 CB, The Netherlands
e-mail: j.p.vanbuijtenen@tudelft.nl

1Present address: École Polytechnique Fédérale de Lausanne (EPFL), Lausanne CH-1015, Switzerland.

Contributed by the Manufacturing Materials and Metallurgy Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received March 9, 2016; final manuscript received March 22, 2016; published online May 3, 2016. Editor: David Wisler.

J. Eng. Gas Turbines Power 138(11), 112101 (May 03, 2016) (11 pages) Paper No: GTP-16-1101; doi: 10.1115/1.4033185 History: Received March 09, 2016; Revised March 22, 2016

Compressor impellers for mass-market turbochargers are die-casted and machined with an aim to achieve high dimensional accuracy and acquire specific performance. However, manufacturing uncertainties result in dimensional deviations causing incompatible operational performance and assembly errors. Process capability limitations of the manufacturer can cause an increase in part rejections, resulting in high production cost. This paper presents a study on a centrifugal impeller with focus on the conceptual design phase to obtain a turbomachine that is robust to manufacturing uncertainties. The impeller has been parameterized and evaluated using a commercial computational fluid dynamics (CFDs) solver. Considering the computational cost of CFD, a surrogate model has been prepared for the impeller by response surface methodology (RSM) using space-filling Latin hypercube designs. A sensitivity analysis has been performed initially to identify the critical geometric parameters which influence the performance mainly. Sensitivity analysis is followed by the uncertainty propagation and quantification using the surrogate model based Monte Carlo simulation. Finally, a robust design optimization has been carried out using a stochastic optimization algorithm leading to a robust impeller design for which the performance is relatively insensitive to variability in geometry without reducing the sources of inherent variation, i.e., the manufacturing noise.

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Figures

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Fig. 1

Deterministic versus robust designs

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Fig. 2

Machining of an impeller wheel

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Fig. 3

Flow chart for robust design optimization methodology applied for the turbocharger compressor impeller

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Fig. 4

The turbocharger compressor

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Fig. 5

Compressor parameterization

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Fig. 6

Geometric model and grid

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Fig. 7

Performance sensitivity analysis using the surrogate model and comparison with CFD

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Fig. 8

Sensitivity ranking (a) pressure ration and (b) isentropic efficiency

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Fig. 9

Probability distributions of variation in impeller pressure ratio and isentropic efficiency

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Fig. 10

Pareto optimal solutions

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Fig. 11

Schematic comparison between baseline impeller and optimized robust impeller designs

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Fig. 12

Probability distributions of robust impeller designs and comparison with the baseline (denoted by “Bsl” in the plots): (a) impeller A (white histogram-baseline, gray histogram-robust), (b) impeller B (white histogram-baseline, gray histogram-robust), and (c) impeller C (white histogram-baseline, gray histogram-robust)

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