Design optimization of a 2D blade by means of milling tool path

Vessaz, Christian; Tournier, Christophe; Münch, Cécile; Avellan, François

doi:10.1016/j.cirpj.2013.05.002

Cited by 13 publications

(8 citation statements)

References 21 publications

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“…However, a coarse resolution has to be selected for the numerical simulations in order to evaluate many different bucket geometries in a reasonable computing time for the exploration and dimension reduction purpose pursued in the last part of the paper. But the same simulation setup with a fine resolution can be applied for solving the reduced optimization sub-problems as in Vessaz et al (2013).…”

Section: Resultsmentioning

confidence: 99%

Toward design optimization of a Pelton turbine runner

Vessaz

Andolfatto

Avellan

et al. 2016

Struct Multidisc Optim

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The objective of the present paper is to propose a strategy to optimize the performance of a Pelton runner based on a parametric model of the bucket geometry, massive particle based numerical simulations and advanced optimization strategies to reduce the dimension of the design problem. The parametric model of the Pelton bucket is based on four bicubic Bézier patches and the number of free parameters is reduced to 21. The numerical simulations are performed using the finite volume particle method, which benefits from a conservative, consistent, arbitrary Lagrangian Eulerian formulation. The resulting design problem is of High-dimension with Expensive Black-box (HEB) performance function. In order to tackle the HEB problem, a preliminary exploration is performed using 2'000 sampled runners geometry provided by a Halton sequence.

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Section: Resultsmentioning

confidence: 99%

Toward design optimization of a Pelton turbine runner

Vessaz

Andolfatto

Avellan

et al. 2016

Struct Multidisc Optim

Self Cite

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“…Hsieh and Chu 12 showed that the control of machining error in five-axis flank milling is quite a difficult task and requires systematic approach such as particle swarm optimization over the existing ad hoc approaches such as surface ruling and tilting cutting tools at certain angle. Vessaz et al 13 demonstrated the importance of selecting proper tool path while end milling of two-dimensional (2D) blades. It was highlighted that the selection of improper tool path will result in significant surface error on the turbine blades and quite different hydraulic properties.…”

Section: Previous Workmentioning

confidence: 99%

Machining of curved geometries with constant engagement tool paths

Desai

Rao

2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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End milling of the curved surfaces is characterized by significant amount of engagement variation along the tool path which results in deflection-induced surface error on the machined components. Feed rate regulation cannot be used in this case to minimize the surface errors as it necessitates continuous change in feed rate along the tool path which deteriorates surface finish and lowers productivity. Another approach in the form of tool path modification scheme was also proposed in the literature to minimize engagement variation at corners of a pocket. This approach has been effective in reducing fluctuations of engagement at corners and cannot be applied directly in machining of curved geometries where engagement variation is continuous along the entire tool path. Keeping these limitations in focus, a new methodology is proposed in this article to minimize surface error variation that modifies machining strategy for the curved components. The strategy proposes machining of the curved components into two different stages: first, generating the modified semi-finishing geometry using algorithm proposed in this article and then producing the desired geometry using conventional contour parallel tool path. The methodology generates the modified semi-finishing geometry such that the engagement offered is constant when a finishing pass is made. The effectiveness of the proposed methodology has been verified by performing computational studies and machining experiments on typical curved geometries. It is observed that the proposed methodology is quite effective in minimizing the variation in the surface error on the machined components.

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“…The main objective of the first technique is to ensure curvature continuity of multisegmented curves and reduce the number of design parameters. 18 Although researchers have made great progress in the objective, the second technique is highlighted for the property of directly linked to key parameters. Admittedly, a smaller number of design parameters might reduce the variety of possible shape in design process.…”

Section: Parametric Design Of 2d Profilementioning

confidence: 99%

“…A robust hybrid (structured/unstructured) mesh 18 is shown in Figure 6, which has a structured O-mesh between Sð,Þ and its offset, and an unstructured triangular mesh between the offset and fluid domain. The structured mesh can control local refinement effectively and preserve good orthogonality at the boundary, while the unstructured mesh can easily accommodate a wide range of the fluid domain and a more possible relative position of the offset.…”

Section: Performance Objectsmentioning

confidence: 99%

Constraints and CFD simulation-based parametric reconstruction for 2D blade profile in reverse engineering

Zhang

Chen

2015

Proceedings of the Institution of Mechanical Engineers, Part G:

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Blade profile plays an extremely important role in the aerodynamic performance of turbomachinary. However, in the process of secondary machining for near-net shape blade and serviced blade, the deviation between nominal profile and measured data can raise serious problems for NC tool path generation. It is even worse that unreasonable reconstruction may be responsible for the deteriorated aerodynamic performance and subsequent high in-service cost. This paper presents a parametric reconstruction strategy for 2D blade profile in reverse engineering. The reconstruction profile approaches to the nominal model and its performance is proved to be more acceptable. This consists in the optimization of parametric geometry (modeling and modification) based on parameter constraints and computational fluid dynamics simulation rather than measured data itself. Some practical examples are used to demonstrate the usefulness and superiority of the strategy.

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Design optimization of a 2D blade by means of milling tool path

Cited by 13 publications

References 21 publications

Toward design optimization of a Pelton turbine runner

Toward design optimization of a Pelton turbine runner

Machining of curved geometries with constant engagement tool paths

Constraints and CFD simulation-based parametric reconstruction for 2D blade profile in reverse engineering

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