ATCx Honeywell Presentation PDF

June 18, 2014
Structural Optimization of
Turbine Engine Components
for a Competitive Advantage
Don Holcomb, Ph.D., MBB
Page 0
2014 Honeywell International Inc.
BP13-266-0
Honeywell.com
Outline
Honeywell - overview
The design problem
Optimize subject to ever changing constraints
Turbine engine design

The process
The opportunity
Example of component optimization

Bypass duct
Frame
Implication for improved system design

Conclusion:
Page 1
Optimization provides a
competitive advantage.
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Honeywell.com
Honeywell International Overview
$40.3-40.7B
in Sales*
54%
Sales Outside U.S.
1,300 sites, 70 countries

132,000 employees
22,000 engineers
Morristown, NJ
headquarters
Fortune 100
Aerospace
Performance
Materials and
Technologies
Automation and
Control Solutions
Transportation
Systems
*2014 guidance, April 2013
Page 2
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Honeywell.com
Honeywells Businesses
Aerospace
Automation and
Control Solutions
Performance
Materials and
Technologies
Transportation
Systems
Phoenix, AZ
Headquarters
Minneapolis, MN
Headquarters
Morristown, NJ
Headquarters
Rolle, Switzerland
Headquarters
$12.1-12.3 billion
sales*
$16.4-16.6 billion
sales*
$6.9-7.0 billion
sales*
$3.6-3.7 billion
sales*
*2013 guidance, April 2013
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Design: Matches Requirements to Capability

Our product development
philosophy attempts to produce a
design that
matches production feasibility
with customer expectation.
CUSTOMER
REQUIREMENTS
DESIGN
PRODUCTION
CAPABILITY
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Design as an Optimization Problem

The design problem:
Max: Earning = value - cost
Subject To: Constraints
(customer, regulatory, internal)
Constraints change as the
design evolves.
Internal and external constraints
Customers perception of value changes
Identifying feasible designs of a complex system is
difficult.
Designs that may appear to be feasible, may be
infeasible upon closer review.
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Now, on to Aircraft Engines Design

HTF7000
Highly Successful 14-year Old Design, but a 2014

Engine Design Must Have Greater Power Density
Page 6
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How Does a New Engine Design Evolve?

Gas turbine concept design can be viewed as a
hierarchical process
1) Thermodynamics
2) Flowpath generation
3) Airfoils
4) Disks
Rotating components,
internal and external
flowpaths
5) Shafts
6) Cases
7) Frames
Static features
8) Nacelles
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Current State of Component Design

Due to fewer constraints, structures often take the
unbounded left-over space
Tightly constrained design space.

Adding mass may hurt
Small changes to the optimal design
may result in an infeasible design.
Design established and set in early
design phases.
Usually adding more material solves

design issues.
Changes are common in late stages to
accommodate requirement changes
and issues with other components.
Historical design process has lead to

sub-optimized designs for weight.
Page 8
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Honeywell / Altair Example: Outer Fan Ducts

Frame Flange
Aft Mount
Aft Outer Fan Duct

Flange
Complex Load
Cases
Forward Outer Bypass
Duct (FOBD)
Aft Outer Fan

Duct Ring
Aft Outer Bypass Duct (AOBD)

View From Above, Aft, Inboard
Initial: > 500 lb of Aluminum forgings

Final: ~53 lb Hogouts
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FOBD & AOBD Topology Optimization

Topology Results View 1
Original Design
Page 10
Topology Load Paths

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Topology Results View 2
Topology Load Paths
Original Design
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Topology Results and Interpretation
Topology Interpretation
Page 12
Topology Load Paths

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FOBD and AOBD Optimization Final Results

Optimization Weight Results
% Reduction
FOBD
27.0%
AOBD
29.5%
Total Weight
28.6%
Weight Reduction Results Very Significant

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HTF7000 Investment Cast Front Frame

Complexity Is Everywhere
Front Perspective
Page 14
Back Perspective
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Front Frame Structural Requirements

Primary engine to aircraft mount structure
Loads generated from:
Engine in flight maneuvers (complex matrix)
Fan blade-out dynamic event
Enormously complex event; major damage allowed
Large, medium, and small bird ingestion event

Very complex events, major damage allowed; 2 minute engine operation;
no damage
Fan blade ice shed scenarios

Post-blade-out windmilling fly home loads
Discrete source damage events e.g., fire, rotor burst, etc.

Provide proper placement and stiffness for rotor bearings
Plus many non-structural requirements:
Guides airflow and supports many external components
Provide oil carrying sumps and services
DFx: x assembly, reparability, cost, manufacture
Page 15
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Honeywell Front Frame

OptiStruct Optimized Frame Geometry
Mid-ring Stiffeners Were
Scalloped to Lower
Mass and Help Reduce
Stresses in Outer Struts
Forward
Frame Part
% Weight
Savings
Outer Ring
0.3%
Mid Ring
11.5%
Inner Cone
31.0%
Struts
0.0%
Total
9.7%
Weight Reduction Results

Very Significant
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Optimized System from Optimized Components

Establish performance and feasible region boundaries
Predicted performance before production.
Each performance curve is a loci of optimal points.
Impeller Clearance vs Duct Stiffness
Duct Stiffness vs Weight
Stiffness
Stiffness
Component
Clearance
Clearance
Lose
Stiff
System
Tight
Soft
Light
Soft
Weight
Weight
Heavy
Stiff
Stiffness
Stiffness
Topological optimization of components

provides for a more optimal system design.
Page 17
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Summary and Final Thoughts

Gas turbine industry is rapidly moving towards
sophisticated structural optimization
What is possible?
Emergence of tools, such as OptiStruct, and processes to use the
power of new tools will enable dramatically improved structures
design
What is the new business mind-set and expectation?

Growing awareness of the low hanging fruit of structure weight
reduction potential is driving the efforts and trend
How will we fully leverage non-conventional geometries?

New manufacturing processes take advantage of arbitrary
geometries (e.g., additive manufacturing)
Topological optimization creates greater product value

and may reduce cost
Enables more competitive product offering.

Page 18
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June 18, 2014

2014 Honeywell International Inc.

Turbine engine design

Example of component optimization

Implication for improved system design

Honeywell International Overview

1,300 sites, 70 countries

*2014 guidance, April 2013

2014 Honeywell International Inc.

2014 Honeywell International Inc.

Design: Matches Requirements to Capability

2014 Honeywell International Inc.

Design as an Optimization Problem

2014 Honeywell International Inc.

Now, on to Aircraft Engines Design

Highly Successful 14-year Old Design, but a 2014

2014 Honeywell International Inc.

How Does a New Engine Design Evolve?

2014 Honeywell International Inc.

Current State of Component Design

Tightly constrained design space.

Usually adding more material solves

Historical design process has lead to

2014 Honeywell International Inc.

Honeywell / Altair Example: Outer Fan Ducts

Aft Outer Fan Duct

Aft Outer Fan

Aft Outer Bypass Duct (AOBD)

Initial: > 500 lb of Aluminum forgings

2014 Honeywell International Inc.

FOBD & AOBD Topology Optimization

Topology Load Paths

FOBD & AOBD Topology Optimization

Topology Load Paths

2014 Honeywell International Inc.

FOBD & AOBD Topology Optimization

Topology Load Paths

FOBD and AOBD Optimization Final Results

Weight Reduction Results Very Significant

2014 Honeywell International Inc.

HTF7000 Investment Cast Front Frame

Front Frame Structural Requirements

Large, medium, and small bird ingestion event

Fan blade ice shed scenarios

Discrete source damage events e.g., fire, rotor burst, etc.

2014 Honeywell International Inc.

Honeywell Front Frame

Weight Reduction Results

2014 Honeywell International Inc.

Optimized System from Optimized Components

Duct Stiffness vs Weight

Topological optimization of components

2014 Honeywell International Inc.

Summary and Final Thoughts

What is the new business mind-set and expectation?

How will we fully leverage non-conventional geometries?

Topological optimization creates greater product value

Enables more competitive product offering.

2014 Honeywell International Inc.