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The purpose of this paper is to improve the hydraulic efficiency without changing the overall dimension. The blade profile optimization design of the aero-centrifugal pump based on the biharmonic equation surrogate model has been studied.

First of all, Bezier curves and linear function are used to control the annular angle distribution and the stacking angle of blade profile under the MATLAB platform. Grid independence analysis has been studied to find the finest mesh scheme. After the precision comparison of test data and computation fluid dynamics 15 sets of design parameters are carried out as the boundary condition of the biharmonic equation. The efficiency surrogate model of the biharmonic equation is constructed via iteratively solving of a discrete difference equation. The other two surrogate models of response surface model (RSM) and radial basis function neural network surrogate model (RBFNNSM) are compared with the biharmonic equation surrogate model by the standard of modified complex correlation coefficient R² and root mean square deviation (RSME). Finally, the artificial fish swarm algorithm has been used to find the global optimal design parameters with the objective function of highest efficiency.

The results show that the design parameters code conversion method can reduce the number of optimization parameters from five to three, makes the design space become a cube, and compared with RSM and RBFNNSM, the biharmonic equation surrogate model has higher precision with R² is 0.8958, RSME is 0.1382. The final optimum result of AFSA is at the point of [1 −1 −1]. The internal flow field analysis shows that after optimization the outlet relative velocity becomes more uniform and the wake effect has been significantly decreased. The hydraulic efficiency of the optimized pump is about 59.45 per cent increasing 5.4 per cent compared with a prototype pump.

This study developed a new method to optimize the design parameters of aero-centrifugal pump impeller based on biharmonic equation surrogate model, which had a good agreement with experimental values within just 15 sets of the original design. The optimization results shows that the method can improve the hydraulic efficiency significantly.

Remanufacturing of worn blades with various defects normally requires processes such as scanning, regenerating a geometrical reference model, additive manufacturing (AM) through laser cladding, adaptive machining and polishing and quality inspection. Unlike the manufacturing process of a new part, the most difficult problem for remanufacturing such a complex surface part is that the reference model adaptive to the worn part is no longer available or useful. The worn parts may suffer from geometrical deformation, distortion and other defects because of the effects of harsh operating conditions, thereby making their original computer aided design (CAD) models inadequate for the repair process. This paper aims to regenerate the geometric models for the worn parts, which is a key issue for implementing AM to build up the parts and adaptive machining to reform the parts. Unlike straight blades with similar cross sections, the tip geometry of the worn tip of a twist blade needs to be regenerated by a different method.

This paper proposes a surface extension algorithm for the reconstruction of a twist blade tip through the extremum parameterization of a B-spline basis function. Based on the cross sections of the scanned worn blade model, the given control points and knot vectors are firstly reconstructed into a B-spline curve D. After the extremum of each control point is calculated by extremum parameterization of a B-spline basis function, the unknown control points are calculated by substituting the extremum into the curve D. Once all control points are determined, the B-spline surface of the worn blade tip can be regenerated. Finally, the extension algorithm is implemented and validated with several examples.

The proposed algorithm was implemented and verified through the exampled blades. Through the extension algorithm, the tip geometry of the worn tip of a twist blade can be regenerated. This method solved a key problem for the repair of a twist blade tip. It provides an appropriate reference model for repairing worn blade tips through AM to build up the blade tip and adaptive machining/polishing processes to reform the blade geometry.

The extension errors for different repair models are compared and analyzed. The authors found that there are several factors affecting the accuracy of the regenerated model. When the cross-section interval and the extension length are set properly, the restoration accuracy for the blade tip can be improved, which is acceptable for the repairing.

The lack of a reference geometric model for worn blades is a significant problem when implementing blade repair through AM and adaptive machining processes. Because the geometric reference model is unavailable for the repair process, reconstruction of the geometry of a worn blade tip is the first crucial step. The authors proposed a surface extension algorithm for the reconstruction of a twist blade tip. Through the implementation of the proposed algorithm, the blade tip model can be regenerated.

Remanufacturing of worn blades with various defects is highly demeaned for the aerospace enterprises considering sustainable development. Unlike straight blades, repair of twist blades encountered a very difficult problem because the geometric reference model is unavailable for the repair processes. This paper proposed a different method to generate the reference model for the repair of a twist blade tip. With this model, repair of twist blades can be implemented through AM to build up the blade tip and adaptive machining to subtract the extra material.

The authors proposed a surface extension algorithm to reconstruct the geometric model for repair of twist blades.

For an axial-flow compressor rotor, the upstream inflow conditions will vary as the aircraft faces harsh flight conditions (such as taking off, landing or maneuvering) or the whole compressor operates at off-design conditions. With the increase of upstream boundary layer thickness, the rotor blade tip will be loaded and the increased blade load will deteriorate the shock/boundary layer interaction and tip leakage flows, resulting in high aerodynamic losses in the tip region. The purpose of this paper is to achieve a better flow control for tip secondary flows and provide a probable design strategy for high-load compressors to tolerate complex upstream inflow conditions.

This paper presents an analysis and application of shroud wall optimization to a typical transonic axial-flow compressor rotor by considering the inlet boundary layer (IBL). The design variables are selected to shape the shroud wall profile at the tip region with the purpose of controlling the tip leakage loss and the shock/boundary layer interaction loss. The objectives are to improve the compressor efficiency at the inlet-boundary-layer condition while keeping its aerodynamic performance at the uniform condition.

After the optimization of shroud wall contour, aerodynamic benefits are achieved mainly on two aspects. On the one hand, the shroud wall optimization has reduced the intensity of the tip leakage flow and the interaction between the leakage and main flows, thereby decreasing the leakage loss. On the other hand, the optimized shroud design changes the shock structure and redistributes the shock intensity in the spanwise direction, especially weakening the shock near the tip. In this situation, the shock/boundary layer interaction and the associated flow separations and wakes are also eliminated. On the whole, at the inlet-boundary-layer condition, the compressor with optimized shroud design has achieved a 0.8 per cent improvement of peak efficiency over that with baseline shroud design without sacrificing the total pressure ratio. Moreover, the re-designed compressor also maintains the aerodynamic performance at the uniform condition. The results indicate that the shroud wall profile has significant influences on the rotor tip losses and could be properly designed to enhance the compressor aerodynamic performance against the negative impacts of the IBL.

The originality of this paper lies in developing a shroud wall contour optimization design strategy to control the tip leakage loss and the shock/boundary layer interaction loss in a transonic compressor rotor. The obtained results could be beneficial for transonic compressors to tolerate the complex upstream inflow conditions.

This study aims to use computational fluid dynamics (CFD) to understand and quantify the overall blockage within a transonic axial flow compressor (AFC), and to develop an efficient collaborative design optimization method for compressor aerodynamic performance and stability in conjunction with a surrogate-assisted optimization technique.

A quantification method for the overall blockage is developed to integrate the effect of regional blockages on compressor aerodynamic stability and performance. A well-defined overall blockage factor combined with efficiency drives the optimizer to seek the optimum blade designs with both high efficiency and wide-range stability. An adaptive Kriging-based optimization technique is adopted to efficiently search for Pareto front solutions. Steady and unsteady numerical simulations are used for the performance and flow field analysis of the datum and optimum designs.

The proposed method not only remarkably improves the compressor efficiency but also significantly enhances the compressor operating stability with fewer CFD calls. These achievements are mainly attributed to the improvement of specific flow behaviors oriented by the objectives, including the attenuation of the shock and weakening of the tip leakage flow/shock interaction intensity.

CFD-based design optimization of AFC is inherently time-consuming, which becomes even trickier when optimizing aerodynamic stability since the stall margin relies on a complete simulation of the performance curve. The proposed method could be a good solution to the collaborative design optimization of aerodynamic performance and stability for transonic AFC.

The aim of the paper is to provide an economically viable solution for the blade repair process. There is a continual increase in the repair market, which requires an increased level of specialised technology to reduce the repair cost and to increase productivity of the process.Design/methodology/approach – This paper introduces the aerospace component defects to be repaired. Current repair technologies including building‐up and machining technology are reviewed. Through the analysis of these available technologies, this paper proposes an integrated repair strategy through information integration and processes concentration.Findings – Provides detailed description and discussion for the repair system, including 3D digitising system, repair inspection, reverse engineering‐based polygonal modelling, and adaptive laser cladding and adaptive machining process.Originality/value – This paper describes a 3D non‐contact measurement‐based repair integration system, and provides a solution to create an individual blade‐oriented nominal model to achieve adaptive repair process (laser cladding/machining) and automated inspection.

In this paper, a turbine blade was optimized by multidisciplinary design optimization (MDO) method. This turbine blade optimization is based on the optimization frame software iSIGHT, in which four disciplines (aerodynamics, thermal dynamics, structural mechanics and structural dynamics) have been integrated. Two commercial discipline analysis soft wares, NUMECA and ANSYS, are coupled in the platform iSIGHT. The three dimensional (3‐D) model of a blade was firstly parameterized. And then a set of parameters are chosen to optimize the blade to obtain the better overall properties. The result shows that the overall performances of the turbine blade have been improved remarkably after it is optimized by using the MDO method.

This paper aims to conduct the optimization of the multi-stage gas turbine with the effect of the cooling air injection based on the adjoint method.

Continuous adjoint method is combined with the S2 surface code.

The optimization of the stagger angles, stacking lines and the passage can improve the attack angles and restrain the development of the boundary, reducing the secondary flow loss caused by the cooling air injection.

The aerodynamic performance of the gas turbine can be improved via the optimization of blade and passage based on the adjoint method.

The results of the first study on the adjoint method applied to the S2 surface through flow calculation including the cooling air effect are presented.

This study aims to complete the optimization design of a centrifugal impeller with both high aerodynamic efficiency and good structural machinability.

First, the design parameters were derived from the blade loading distribution and the meridional geometry in the impeller three-dimensional (3D) inverse design. The blade wrap angle at the middle span surface and the spanwise averaged blade angle at the blade leading edge obtained from inverse design were chosen as the machinability objectives. The aerodynamic efficiency obtained by computational fluid dynamics was selected as the aerodynamic performance objective. Then, using multi-objective optimization with the optimal Latin hypercube method, quadratic response surface methodology and the non-dominated sorting genetic algorithm, the trade-off optimum impellers with small blade wrap angles, large blade angles and high aerodynamic efficiency were obtained. Finally, computational fluid dynamics and computer-aided manufacturing were performed to verify the aerodynamic performance and structural machinability of the optimum impellers.

Providing the fore maximum blade loading distribution at both the hub and shroud for the 3D inverse design helped to promote the structural machinability of the designed impeller. A straighter hub coupled with a more curved shroud also facilitated improvement of the impeller’s structural machinability. The preferred impeller was designed by providing both the fore maximum blade loading distribution at a relatively straight hub and a curved shroud for 3D inverse design.

The machining difficulties of the designed high-efficiency impeller can be reduced by reducing blade wrap angle and enlarging blade angle at the beginning of impeller design. It is of practical value in engineering by avoiding the follow-up failure for the machining of the designed impeller.

The application of thermal barrier coatings (TBCs) allows aero-engine blades to operate at higher temperatures with higher efficiency. The preparation of the TBCs increases the surface roughness of the blade, which impacts the thermal cycle life and thermal insulation performance of the coating. To reduce the surface roughness of blades, particularly the blades with small size and complex curvature, this paper aims to propose a method for industrial robot polishing trajectory planning based on on-site measuring point cloud.

The authors propose an integrated robotic polishing trajectory planning method using point cloud processing technical. At first, the acquired point cloud is preprocessed, which includes filtering and plane segmentation algorithm, to extract the blade body point cloud. Then, the point cloud slicing algorithm and the intersection method are used to create a preliminary contact point set. Finally, the Douglas–Peucker algorithm and pose frame estimation are applied to extract the tool-tip positions and optimize the tool contact posture, respectively. The resultant trajectory is evaluated by simulation and experiment implementation.

The target points of trajectory are not evenly distributed on the blade surface but rather fluctuate with surface curvature. The simulated linear and orientation speeds of the robot end could be relatively steady over 98% of the total time within 20% reduction of the rest time. After polishing experiments, the coating roughness on the blade surface is reduced dramatically from Ra 7–8 µm to below Ra 1.0 µm. The removal of the TBCs is less than 100 mg, which is significantly less than the weight of the prepared coatings. The blade surface becomes smoothed to a mirror-like state.

The research on robotic polishing of aero-engine turbine blade TBCs is worthwhile. The real-time trajectory planning based on measuring point cloud can address the problem that there is no standard computer-aided drawing model and the geometry and size of the workpiece to be processed differ. The extraction and optimization of tool contact points based on point cloud features can enhance the smoothness of the robot movement, stability of the polishing speed and performance of the blade surface after polishing.

Modern unmanned air vehicles (UAVs) are usually equipped with rotors connected to electric motors that enable them to hover and fly in all directions. The purpose of the paper is to design optimal composite rotor blades for such small UAVs and investigate their aerodynamic performances both computationally and experimentally.

Artificial intelligence method (genetic algorithm) is used to optimize the blade airfoil described by six input parameters. Furthermore, different computational methods, e.g. vortex methods and computational fluid dynamics, blade element momentum theory and finite element method, are used to predict the aerodynamic performances of the optimized airfoil and complete rotor as well the structural behaviour of the blade, respectively. Finally, composite blade is manufactured and the rotor performance is also determined experimentally by thrust and torque measurements.

Complete process of blade design (including geometry definition and optimization, estimation of aerodynamic performances, structural analysis and blade manufacturing) is conducted and explained in detail. The correspondence between computed and measured thrust and torque curves of the optimal rotor is satisfactory (differences mostly remain below 15%), which validates and justifies the used design approach formulated specifically for low-cost, small-scale propeller blades. Furthermore, the proposed techniques can easily be applied to any kind of rotating lifting surfaces including helicopter or wind turbine blades.

Blade design methodology is simplified, shortened and made more flexible thus enabling the fast and economic production of propeller blades optimized for specific working conditions.