© Rolls-Royce plc 2009The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.Published by NATO Research and Technology Organization (RTA) with permission

Lecture Series AVT-167

Case Study 3: ComponentsHigh Pressure Compressor and Turbine Disk, Structural Casings

A. Karl, Rolls-Royce

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Outline

5 steps for Robust DesignBasic approach for automated DesignExamplesSummaryQuestions

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Design for Six Sigma Toolset

Integrated Frameworks

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

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Basic Process

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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

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Examples – Component Level

Turbine Blade – Disc attachmentTurbine Disc life assessmentEffect of Manufacturing tolerances on

compressor discsRobustness Assessment of a structural

casing

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Blade – Disc connection example: Process Definition

integrated process

Geometry model

Analysis model 2

Analysis model 1

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Blade – Disc connection example: Results of Optimisation

Pareto front (best possible combinations)

manual optimisation

improvement possibilities

Criteria 1

Crit

eria

2

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Turbine Disc Life Prediction:Variability Assessment and Weight Reduction

heat transfer/ nominal heat transfer

Dia

phra

gmLi

fe/N

omin

alD

iaph

ragm

Life

1 1.25 1.5 1.75 20.5

0.6

0.7

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

Variability assessmentfor disc life

Disc weight minimisation

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Compressor Disc Design:Monte Carlo Simulation

Manufacturing tolerances are transformed into

Mass variability Movement variability Stress variability Etc.

Proper assessment of the design becomes possible

MCS using ResponseSurface Methods

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Structural Casing example: Process Definition

STEP Translator

STEP File

Cost ModelsUnit Cost

FE AnalysisLifing Parameter

Process IntegrationDesign Parameters & Tolerances

Boundary Conditions

Check Objectives to

Exit Loop

GeometryCreation

Analysis Model

Part File

Part Parameter & Expressions

Derived Manufacturing

Parameters

Design Parameters

Manufacturing

Scrap & Rework Cost

Manufacture Cost

Process Capability

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Structural Casing example: Robustness Results

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SummarySeveral 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

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