ACCURATE MULTIOBJECTIVE DESIGN OPTIMIZATION OF NASA ROTOR 37 Ernesto Benin Deparient of Mechanical Engineering - Univesity of Padova, Kaly Via Veneia, {38131 Padova emestobeniniunigd it ABSTRACT ‘An accurate method for transorie. compressor multi-objective design optimization was ‘developed and applied to the NASA rotor 37, a test case representative of complex thres- mensional viscous flow structures in tansonic blades. The optimization problem consisted in maximizing the isentropic efficiency ofthe rotor and in maximizing its pressure rato a the design point, using a constraint on the mass flow rate. The «wo objectives were taken into account simultaneously, using a Pareto multi-objective approach implemented in a novel evolutionary algorithm. The optimization algorithm was coupled with the chres-dimensional Navier-Stokes cade CFX-TASCIlow, which was used forthe aerodynamic analysis of blade designs, Prior 19 optimization, the CFD code was accurately validated against the available ‘experimental data by means ofa systematic sensitivity analysis oa the influence of the code's ‘configuration {in tems of grid parameters, turbulence models and solution schemes) on accuracy of the numerical computations. The optimal rotor configurations, which corresponded to the maxitnam pressure ratio and maximum ficiency, were obtained and compared 10 the original design. The reasons for improved performance were discussed cially, 1, INTRODUCTION ‘Transonie compressors are use in sireraft engines fo develop the highest values of both cffcieney and the compression ratio, Performance of suck machines has today reached a very high level but engine manufacturers are oriented toward increasing it further. A small iuerement in efficiency, for instance, ean reslt in huge savings in fuel eosts and determine & key factor for product success. Another important Factor sees on improvements in the stage pressure ratio, which can make it possible to reduce the engine weight and size and, therefore, investment and oporaional cost. these compressors, the portion of the eotor clase to the hab operates at high subsonic relative velocities, while inthe outer pat the flow is definitely supersonic. In such coalitions, the rotor experiences the existence of intense shock waves which are generated close to blade tip and aver part ofthe span, Those shock waves are responsible fr high aerodynamic losses ‘nd entropy generasion which negatively influence the overall efficieney but, at the same time, they contribute to achieving a high compression rato aa result of te intense diffusion the flow is subject io when passing through the shock front. ‘The presence of complex shock structares that interact with the mein flow end wall ‘ounery layers explains why the design of such machines is so challenging, In Tact, the {89 CONGRESSOANNUALEATI-Gengra2008 1193194 esign priniple isnot to avoid shocks (as isthe ease in subsonic compressors), but to control their locations and strengths in order to obtain maximum pecformance. Computational Fluid ‘Dynamics (CFD) is of practical importance for this purpose, because it helps the designer to beitor understand the features of the flow field anc establishes the way the peometry of the blade has to be designed and, if necessary, modified. Examples of CED calculations on transonic compressor blades can be casly found in the open literature (see, among athe, ‘Miller and Bryans, 1988; Hah and Wennerstrom, 1991; Hah ct al, 1998), Novier Stokes ‘analyses, in paticular, make it possible to deal with the reel throe-dimonsional design problem and to study the effect of changes in the 3D blade shape. These include both the application of high-performance airuls for transonie bladings, as well the use of sweep and {ean in blade radial stacking (Prince, 1980; Neubert ot al., 1990; Wadis ct al, 1987), CFD alone can be very useful in the framawork of a conventional tialnd-eror procedure of a transonic blade, but it becomes even more powerful when coribined with an ‘optimization routine. This aspect has recently boe3 investigated by several researchers and the results documented in relevant publications. Leo and Kim (2000) used « gradient-based rethod to optimize the blades of transonic compressor using the 3D. Navier-Stokes ‘equations. Alu and Kim (2002) developed an optimization technique for the NASA rotor 37 based on the response surface method, Oyama etal (2002) used evolutionary algorithms in the redesign of the blade of NASA rotor 67. The latter was also adopted. by Tiow and ‘Zangeneh (2002) as atest case forthe application of « 3D inverse design methodology. Tiow ct al, (2002) developed and applied an inverse design technique coupled with « simulated annealing optimization algoritnm. in the design of transonic axial blade cascades. All the ‘works above have in common the fact that optimization methodologies were adopted 10 ‘minimize eerodyanmic losses ‘Tse present work follows an approach that considers more than one objective atthe same time, ie. is based on a multiobjective methodology. [n pasticuler a method for the multe objective problem of optimizing a tansonie rotor blade (belonging to NASA rotor 37) with respect to both aerodynamic efficiency and the pressure ratio was developed. ‘The optimization problem is addressed using a CFD code configuration which results from a rigorous and systematic validation, where the influsnce of grid parameters, turbulence models ‘ad solution schemes on accuracy of numerical computations has been investigated. 2. OPTIMIZATION OF NASA ROTOR 37 Rotor 37 designed by NASA Lewis Research Center is a well documented test case, where strong interactions (such as comer stall, shock/boundary layer, tip-vortex and tp leakage ‘secondary interactions) occur. Even though it was developed more than twenty years ago, Rotor 37 is representative of design and performance levels ofthe most advanced transooic blades usec today in gas turbine inlet stages. Some design infortration and overall stage performance came from Reid and Moore (1978), nd detailed mcasurement data was provided bby Moore and Reid (1980), Some geometrical datils of Rotor 37 ate given i Figure 1. ‘The purpose of the optimization coaidetcd here was 4a maximize the two-objective Faneton: F (nad wo here 7, isthe adiabatic eilciency and p/p} the total-o-otal pressure ratio, both referred to stations 1 and 4 of Figure 1, One operating condition (corresponding 1 98% of the choke ‘ms flow) was considered in the optimization, The inlet total pressure and total temperatureiss vere fixed at p!=101325 Pu and 17?-288.15 K. Tho optimization was cared out using an optimization method which integrates 4 code for 3D blade geometry parameterization, © [Navier-Stokes solver and an optimization algorithm, A detailed deseripion of this method, along with examples ofits application to design optimization of turbomachinery blades ean be found elsewhere (Benin and Toffolo, 2002; Benin, 2003; Benn’ and Toff, 2003). ‘nl drecion Figure J: Meridional geometry and measurement stations of NASA Rotor 37, Dunham (1998). 21 Blade geometry definition Jn order wo make the results of the optimization comparable to those regarding the baseline configuration, the meridional contours of the hub and casing were not modified. In fac, a change in the meridional area would have fu song impact on the aeroiynamie blockage and, therefore, on the compressor flow capacity. The rotor blade geometry was parameterized using three profiles along the span (hub, midspan and tip profiles), each of which was «eseribed by camber and thickness distioutions (Figure 2). These were defined by 4° order Bezier polynomials, where the values ofthe ordinates of the control points (@ for the camber line and, the thickness} were allowed to vary as independent design variables, ‘heioats dsubsten ria i Tas Bose poe on A ce contri deiao ' : Cs vo ‘ bf é gee ee oo fo © aaa, a ee ee ee) attra cl ent oon Ss ae send ee ane Figure 2: Parameterization ofa compressor airfoil ‘The blade surfaee wns then ohinined hy interpolating profile enordnatas in the span direction wing spline curves. By specilying a proper value ofthe @ coordinate ofthe first midspan snd