Applications and enhancements of aircraft design optimization techniques

The aircraft industry has been at the forefront in developing design optimization strategies ever since the advent of high performance computing. Thanks to the large computational resources now available, many new as well as more mature optimization methods have become well established. However, the same cannot be said for other stages along the optimization process - chiefly, and this is where the present thesis seeks to make its first main contribution, at the geometry parameterization stage.The first major part of the thesis is dedicated to the goal of reducing the size of the search space by reducing the dimensionality of existing parameterization schemes, thus improving the effectiveness of search strategies based upon them. Specifically, a refinement to the Kulfan parameterization method is presented, based on using Genetic Programming and a local search within a Baldwinian learning strategy to evolve a set of analytical expressions to replace the standard 'class function' at the basis of the Kulfan method. The method is shown to significantly reduce the number of parameters and improves optimization performance - this is demonstrated using a simple aerodynamic design case study.The second part describes an industrial level case study, combining sophisticated, high fidelity, as well as fast, low fidelity numerical analysis with a complex physical experiment. The objective is the analysis of a topical design question relating to reducing the environmental impact of aviation: what is the optimum layout of an over-the-wing turbofan engine installation designed to enable the airframe to shield near-airport communities on the ground from fan noise. An experiment in an anechoic chamber reveals that a simple half-barrier noise model can be used as a first order approximation to the change of inlet broadband noise shielding by the airframe with engine position, which can be used within design activities. Moreover, the experimental results are condensed into an acoustic shielding performance metric to be used in a Multidisciplinary Design Optimization study, together with drag and engine performance values acquired through CFD. By using surrogate models of these three performance metrics we are able to find a set of non-dominated engine positions comprising a Pareto Front of these objectives. This may give designers of future aircraft an insight into an appropriate engine position above a wing, as well as a template for blending multiple levels of computational analysis with physical experiments into a multidisciplinary design optimization framework

Enhancement of the Mixing Efficiency for a Steam Boiler Premix Channel with a Surrogate Based Optimization

Global warming and the ever-increasing pollutants in the atmosphere force many governments to limit emissions. The use of methane as a fuel is widespread in the boiler industry, due to the low pollutant levels in its exhaust gas products. Nevertheless, in the combustion process, nitrogen and oxygen bind giving rise to a series of molecular compounds called NO x, which are considered pollutants because they react in the atmosphere causing the production of acid rain and reducing the level of ozone [1]. The aim of this work is to improve the mixture quality between fresh air, methane and recirculated exhaust gases introduced within Ecovapor Boiler's Mixing-Channel and, as consequence, to increase the combustion quality and limit the pollution production. The geometry is parameterized within Ansys Space Claim CAD software [2], and gas mixture flow is computed with Ansys Fluent solver [3]. To achieve these goals an automated shape optimization is adopted, which couples the Ansys Workbench environment to Dakota software [4]. In particular, a multi-objective genetic algorithm (MOGA) [5] combined with the Kriging response surface method is used, while the geometries are evaluated by solving for a compressible mixture of non-reacting gases the steady-state Reynolds Average NavierStokes (RANS) equations coupled with the kRealizable turbulence model [6]

ONLINE APPROXIMATION ASSISTED MULTIOBJECTIVE OPTIMIZATION WITH HEAT EXCHANGER DESIGN APPLICATIONS

Computer simulations can be intensive as is the case in Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). The computational cost can become prohibitive when using these simulations with multiobjective design optimization. One way to address this issue is to replace a computationally intensive simulation by an approximation which allows for a quick evaluation of a large number of design alternatives as needed by an optimizer. This dissertation proposes an approach for multiobjective design optimization when combined with computationally expensive simulations for heat exchanger design problems. The research is performed along four research directions. These are: (1) a new Online Approximation Assisted Multiobjective Optimization (OAAMO) approach with a focus on the expected optimum region, (2) a new approximation assisted multiobjective optimization with global and local metamodeling that always produces feasible solutions, (3) a framework that integrates OAAMO with multiscale simulations (OAAMOMS) for design of heat exchangers at the segment and heat exchanger levels, and (4) applications of OAAMO combined with CFD for shape design of a header for a new generation of heat exchangers using Non-Uniform Rational B-Splines (NURBS). The approaches developed in this thesis are also applied to optimize a coldplate used in electronic cooling devices and different types of plate heat exchangers. In addition many numerical test problems are solved by the proposed methods. The results of these studies show that the proposed online approximation assisted multiobjective optimization is an efficient approach that can be used to predict optimum solutions for a wide class of problems including heat exchanger design problems while reducing significantly the computational cost when compared with existing methods

Development of numerical procedures for turbomachinery optimizaion

This Doctoral Thesis deals with high speed turbomachinery optimization and all those tools employed in the optimization process, mainly the optimization algorithm, the parameterization framework and the automatic CFD-based optimization loop. Optimization itself is not just a mean to improve the performance of a generic system, but can be a powerful instigator that helps gaining insight on the physic phenomena behind the observed improvements. As for the optimization engine, a novel surrogate-assisted (SA) genetic algorithm for multi-objective optimization problems, namely GeDEA-II-K, was developed. GeDEA-II-K is grounded on the cooperation between a genetic algorithm, namely GeDEA-II, and the Kriging methodology, with the aim at speeding up the optimization process by taking advantage of the surrogate model. The comparison over two- and three-objective test functions revealed the effectiveness of GeDEA-II-K approach. In order to carry out high speed turbomachinery optimizations, an automatic CFD-based optimization loop built around GeDEA-II-K was constructed. The loop was realized for a UNIX/Linux cluster environment in order to exploit the computational resources of parallel computing. Among the tools, a dedicated parameterization framework for 2D airfoils and 3D blades has been designed based on the displacement filed approach. The effectiveness of both the CFD-based automatic loop and the parameterization was verified on two real-life multi-objective optimization problems: the 2D shape optimization of a supersonic compressor cascade and the 3D shape optimization of the NASA Rotor 67. To better understand the outcomes of the optimization process, a wide section has been dedicated to supersonic flows and their behavior when forced to work throughout compressor cascades. The results obtained surely have demonstrated the effectiveness of the optimization approach, and even more have given deep insight on the physic of supersonic flows in the high speed turbomachinery applications that were studied

Multiobjective Design Optimization Of Gas Turbine Blade With Emphasis On Internal Cooling

In the design of mechanical components, numerical simulations and experimental methods are commonly used for design creation (or modification) and design optimization. However, a major challenge of using simulation and experimental methods is that they are timeconsuming and often cost-prohibitive for the designer. In addition, the simultaneous interactions between aerodynamic, thermodynamic and mechanical integrity objectives for a particular component or set of components are difficult to accurately characterize, even with the existing simulation tools and experimental methods. The current research and practice of using numerical simulations and experimental methods do little to address the simultaneous “satisficing” of multiple and often conflicting design objectives that influence the performance and geometry of a component. This is particularly the case for gas turbine systems that involve a large number of complex components with complicated geometries. Numerous experimental and numerical studies have demonstrated success in generating effective designs for mechanical components; however, their focus has been primarily on optimizing a single design objective based on a limited set of design variables and associated values. In this research, a multiobjective design optimization framework to solve a set of userspecified design objective functions for mechanical components is proposed. The framework integrates a numerical simulation and a nature-inspired optimization procedure that iteratively perturbs a set of design variables eventually converging to a set of tradeoff design solutions. In this research, a gas turbine engine system is used as the test application for the proposed framework. More specifically, the optimization of the gas turbine blade internal cooling channel configuration is performed. This test application is quite relevant as gas turbine engines serve a iv critical role in the design of the next-generation power generation facilities around the world. Furthermore, turbine blades require better cooling techniques to increase their cooling effectiveness to cope with the increase in engine operating temperatures extending the useful life of the blades. The performance of the proposed framework is evaluated via a computational study, where a set of common, real-world design objectives and a set of design variables that directly influence the set of objectives are considered. Specifically, three objectives are considered in this study: (1) cooling channel heat transfer coefficient, which measures the rate of heat transfer and the goal is to maximize this value; (2) cooling channel air pressure drop, where the goal is to minimize this value; and (3) cooling channel geometry, specifically the cooling channel cavity area, where the goal is to maximize this value. These objectives, which are conflicting, directly influence the cooling effectiveness of a gas turbine blade and the material usage in its design. The computational results show the proposed optimization framework is able to generate, evaluate and identify thousands of competitive tradeoff designs in a fraction of the time that it would take designers using the traditional simulation tools and experimental methods commonly used for mechanical component design generation. This is a significant step beyond the current research and applications of design optimization to gas turbine blades, specifically, and to mechanical components, in general

Two-Dimensional-Based Hybrid Shape Optimisation of a 5-Element Formula 1 Race Car Front Wing under FIA Regulations

Front wings are a key element in the aerodynamic performance of Formula 1 race cars. Thus, their optimisation makes an important contribution to the performance of cars in races. However, their design is constrained by regulation, which makes it more difficult to find good designs. The present work develops a hybrid shape optimisation approach to obtain an optimal five-element airfoil front wing under the FIA regulations and 17 design parameters. A first baseline design is obtained by parametric optimisation, on which the adjoint method is applied for shape optimisation via Mesh Morphing with Radial Basis Functions. The optimal front wing candidate obtained outperforms the parametric baseline up to a 25% at certain local positions. This shows that the proposed and tested hybrid approach can be a very efficient alternative. Although a direct 3D optimisation approach could be developed, the computational costs would be dramatically increased (possibly unaffordable for such a complex five-element front wing realistic shape with 17 design parameters and regulatory constraints). Thus, the present approach is of strong interest if the computational budget is low and/or a fast new front wing design is desired, which is a frequent scenario in Formula 1 race car design.The authors want to acknowledge the financial support from the Ramón y Cajal 2021 Excellence Research Grant action from the Spanish Ministry of Science and Innovation (FSE/AGENCIA ESTATAL DE INVESTIGACIÓN), the UMA18-FEDERJA-184 grant, and the Andalusian Research, Development and Innovation Plan (PAIDI—Junta de Andalucia) fundings. Partial funding for open access charge: Universidad de Málag

Multi-objective climb path optimization for aircraft/engine integration using Particle Swarm Optimization

In this article, a new multi-objective approach to the aircraft climb path optimization problem, based on the Particle Swarm Optimization algorithm, is introduced to be used for aircraft–engine integration studies. This considers a combination of a simulation with a traditional Energy approach, which incorporates, among others, the use of a proposed path-tracking scheme for guidance in the Altitude–Mach plane. The adoption of population-based solver serves to simplify case setup, allowing for direct interfaces between the optimizer and aircraft/engine performance codes. A two-level optimization scheme is employed and is shown to improve search performance compared to the basic PSO algorithm. The effectiveness of the proposed methodology is demonstrated in a hypothetic engine upgrade scenario for the F-4 aircraft considering the replacement of the aircraft’s J79 engine with the EJ200; a clear advantage of the EJ200-equipped configuration is unveiled, resulting, on average, in 15% faster climbs with 20% less fuel

An artificial intelligence platform for design optimization and data analysis: application for fire and ventilation problems

This thesis focuses on the development of novel multi-objective software platforms to assist engineering design and investigation, especially for simulation-based indoor environment problems, which always involve multiple evaluation criteria. In addition, this thesis aims to develop new methods to reduce the computational cost associated with the design process. In modern building design, engineers are constantly facing challenging to find an optimal design to maintain a high level of thermal comfort and indoor air quality for occupants while minimizing the system energy consumption. Over the past decades, several algorithms have been proposed and developed for optimizing the heating, ventilation and air conditioning (HVAC) system for indoor environment. Nevertheless, the majority of these optimization algorithms are focused on single objective optimization procedures and require a large training sample for surrogate modelling. For multi-objective HVAC design problems, previous studies introduced an arbitrary weighting factor to combine all design objectives into one single objective function. The near-optimal solutions were however sensitive to the chosen value of the weighting factor. In another hand, the computational cost is very heavy in the computer-aided investigation process of reverse engineering problems. Computational Fluid Dynamics (CFD) aided fire investigation is one of the reverse engineering. With the significant growth of the world population, our cities are becoming more and more crowding. In this situation, any fire occurring would cause severe consequences, including property damage and human injuries or even deaths. In assessing the fire cause, the fire origin determination is a crucial step identifying the origin of fire outbreak and the sequential fire and smoke propagation. Traditionally, fire investigators relied upon the visible fire damages at the fire scene to determine the location of fire originated based on their own professional experience. The fire investigation process is however subject to the expert interpretation inherently embedded in the qualitative analyses. In addition, we are living in an era of big data, where lots amount of data are generating every day, especially in engineering field. Traditional analysis methods are not suitable to handle large amount of data quickly and accurately. In contrast, new techniques such as machine learning are able to deal with big data and extract data features. The main body of this thesis is composed of seven chapters, and the details of each chapter are as the followings: The research background and a comprehensive literature review are described in the first two chapters where the research gaps found in the existing literatures are discussed. From Chapter 3 to Chapter 6, the main contributions of this research are demonstrated. In Chapter 3, a nondominated sorting-based particle swarm optimization (NSPSO) algorithm together with the Kriging method to perform optimization for the HVAC system design of a typical office room was developed. In addition, an adaptive sampling procedure was also introduced to enable the optimization platform to adjust the sampling point and resolution in constructing the training sample. Chapter 4 presents a Multi-fidelity Kriging algorithm to quantitatively determine the fire origin based on the soot deposition patterns predicted by the numerical simulations, which provides an unbiased and fast methodology to assist the fire investigation. A comprehensive multi-objective optimization platform of the ventilation system inside a typical high-speed train (HST) cabin is discussed in Chapter 5, where the NSPSO and the Multi-fidelity Kriging were combined together to reduce computational cost. Chapter 6 demonstrates a successful application of convolutional neural networks (CNN) in vegetation feature analysis to help cut powerline wildfire risk caused by vegetation conduction ignition. Finally, all the contributions in this research are summarised in Chapter 7