Implementation of Thermal Aspects in Topology Optimization in a Multi-Disciplinary framework for a Turbine Rear Structure

Sammanfattning: This thesis investigates the possibilities of implementing thermal aspects in Topology Optimization (TO) of hot engine structures. Topology Optimization is an effective tool for conceptual design in numerous field of applications. At GKN, this optimization technique has previously only been successfully implemented for structures affected by mechanical loads. The aim with this study and the ongoing research at GKN, is to improve the in-house developed multi-disciplinary optimization procedure called Engineering WorkBench (EWB). By expanding the applicability of a more comprehensive TO which includes the thermal expansion. However, since there is no straight forward solution provided by the FE software’s, a better understanding of TO in general and for thermally loaded structures in particular, is needed before deciding on an application strategy.Two approaches for the thermal implementation in TO of the Turbine Rear Structure (TRS) have been studies and evaluated. The first is a stress constrained optimization procedure, based on requirements for the number of thermal load cycles, calculated in CUMFAT, an in-house developed program for life prediction. The second approach is a case trial study of the coupled thermal-mechanical structural optimization. The trials are performed systematically to illustrate what type of geometrical variations one can expect in the TO outcome when varying different factors in the optimization set up, such as the load type magnitude and optimization formulation. The evaluation of these to different approaches will increase the understanding of the challenges involved when performing TO of this type of structure.The complexity of this implementation is clearly demonstrated by the variation in optimization outcome. The results shows the importance of having substantial knowledge about the model, load cases and the optimization purpose before defining the optimization problem. Finally, suggestions for the continuation and implementation of thermal TO in the EWB, are presented.