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Lecture Series AVT-167

Lecture Series AVT-167. Case Study 3: Components High Pressure Compressor and Turbine Disk, Structural Casings A. Karl, Rolls-Royce. Outline. 5 steps for Robust Design Basic approach for automated Design Examples Summary Questions. Integrated Frameworks. Design for Six Sigma Toolset.

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Lecture Series AVT-167

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  1. Lecture Series AVT-167 Case Study 3: Components High Pressure Compressor and Turbine Disk, Structural Casings A. Karl, Rolls-Royce

  2. Outline • 5 steps for Robust Design • Basic approach for automated Design • Examples • Summary • Questions NATO/PFP

  3. Integrated Frameworks Design for Six Sigma Toolset 5 steps to achieve Robust Design • Automate Process • execute design / analysis process without human interaction • Process Integration • build up of integrated processes between various disciplines • Design Exploration • getting an understanding of the design space characteristic • Optimisation • achieve the best compromise regarding all requirements • Robust Design • make sure that the design performs for variable conditions NATO/PFP

  4. Basic Process NATO/PFP

  5. Integrated Frameworks • Enable the linking of simulation tools to • Achieve a considerable speed-up of the simulation task • Achieve multidisciplinary processes across teams and business units • Achieve a standardisation of the used simulation processes NATO/PFP

  6. Examples – Component Level • Turbine Blade – Disc attachment • Turbine Disc life assessment • Effect of Manufacturing tolerances on compressor discs • Robustness Assessment of a structural casing NATO/PFP

  7. Blade – Disc connection example: Process Definition Geometry model Analysis model 1 Analysis model 2 integrated process NATO/PFP

  8. Pareto front (best possible combinations) improvement possibilities Criteria 2 manual optimisation Criteria 1 Blade – Disc connection example: Results of Optimisation NATO/PFP

  9. Turbine Disc Life Prediction:Variability Assessment and Weight Reduction Variability assessment for disc life Disc weight minimisation NATO/PFP

  10. Manufacturing tolerances are transformed into Mass variability Movement variability Stress variability Etc. Proper assessment of the design becomes possible Compressor Disc Design:Monte Carlo Simulation MCS using Response Surface Methods NATO/PFP

  11. STEP Translator FE Analysis STEP File Lifing Parameter Scrap & Rework Cost Manufacturing Manufacture Cost Process Capability Process Integration Design Parameters & Tolerances Check Objectives to Exit Loop Boundary Conditions Structural Casing example: Process Definition Geometry Creation Analysis Model Part File Part Parameter & Expressions Derived Manufacturing Parameters Cost Models Design Parameters Unit Cost NATO/PFP

  12. Structural Casing example: Robustness Results NATO/PFP

  13. Summary • Several examples have shown the benefit of using automated design approaches • Important info can be gained by these methods making the design decisions more focused • Using the info from the automated design approaches the risk in the execution of development programs for complex systems can be reduced NATO/PFP

  14. Questions ? NATO/PFP

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