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NASA NTRS2020

Shape Optimization of Vortex Generators to Control Mack Mode Amplification

This paper demonstrates the potential to use shape optimization for the design of vortex generators in an axisymmetric boundary layer. This shape optimization increases the amplitude of stationary streaks created by streamwise vorticity, with the goal of reducing the amplification of Mack mode instabilities. The test case under consideration matches a trajectory point during the ascent phase of the HIFiRE-1 flight experiment. Wall-mounted vortex generators are added to the cone and their shape is optimized to control the amplification of Mack mode instabilities that are known to initiate laminar-turbulent transition in this flow. An empirical objective function is developed based on the previous studies of optimal streaks. A constraint on the maximum streak amplitude is added to avoid the initiation of bypass transition. The shape optimization is conducted using SU2, an open-source suite for multiphysics simulation and design. A significant improvement is observed in an integral metric of the streak amplitude, while the maximum streak amplitude is maintained close to the baseline level. The qualitative features of the optimized geometry are discussed.

Vortex generators↗

NASA NTRS1992

Improving the efficiency of aerodynamic shape optimization procedures

The computational efficiency of an aerodynamic shape optimization procedure which is based on discrete sensitivity analysis is increased through the implementation of two improvements. The first improvement involves replacing a grid point-based approach for surface representation with a Bezier-Bernstein polynomial parameterization of the surface. Explicit analytical expressions for the grid sensitivity terms are developed for both approaches. The second improvement proposes the use of Newton's method in lieu of an alternating direction implicit (ADI) methodology to calculate the highly converged flow solutions which are required to compute the sensitivity coefficients. The modified design procedure is demonstrated by optimizing the shape of an internal-external nozzle configuration. A substantial factor of 8 decrease in computational time for the optimization process was achieved by implementing both of the design improvements.

Burgreen, Greg W.↗

NASA NTRS2015

Aerodynamic Shape Optimization of a Dual-Stream Supersonic Plug Nozzle

Aerodynamic shape optimization was performed on an isolated axisymmetric plug nozzle sized for a supersonic business jet. The dual-stream concept was tailored to attenuate nearfield pressure disturbances without compromising nozzle performance. Adjoint-based anisotropic mesh refinement was applied to resolve nearfield compression and expansion features in the baseline viscous grid. Deformed versions of the adapted grid were used for subsequent adjoint-driven shape optimization. For design, a nonlinear gradient-based optimizer was coupled to the discrete adjoint formulation of the Reynolds-averaged Navier- Stokes equations. All nozzle surfaces were parameterized using 3rd order B-spline interpolants and perturbed axisymmetrically via free-form deformation. Geometry deformations were performed using 20 design variables shared between the outer cowl, shroud and centerbody nozzle surfaces. Interior volume grid deformation during design was accomplished using linear elastic mesh morphing. The nozzle optimization was performed at a design cruise speed of Mach 1.6, assuming core and bypass pressure ratios of 6.19 and 3.24, respectively. Ambient flight conditions at design were commensurate with 45,000-ft standard day atmosphere.

shape optimization↗

DOE OSTI2025

Integrating Crack Detection and Pipe Shape Optimization for Enhanced Sewage System Durability

Crack detection in underground reinforced concrete pipes has been essential in determining the state of stormwater infrastructure. Detection models have been implemented for detecting cracks and other defects in pipes using CCTV footage for stormwater drainage systems. In addition, Finite element models have been used to determine optimum shapes and pipe thickness for different boundary conditions such as header pipes in power plants. The concept of shape optimization emerges as a crucial factor in power plant design and operation, with the potential to maximize performance while minimizing the use of materials. Shape optimization not only enhances efficiency but also contributes to reducing the environmental footprint. This paper discusses the integration of both topics by using the cracks detected in underground pipes as boundary conditions for shape optimization of the pipes. A machine learning model has been developed which uses limited data for training and outlines the location of detected cracks. A shape optimization methodology is proposed in which ANSYS modules are used to analyze fluid flow and then optimize the shape of the pipe. The crack detection model developed has been applied to a crack detected in lab setting and machine learning model used has an accuracy of 98% using a random forest algorithm.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1997

Gradient-Based Aerodynamic Shape Optimization Using ADI Method for Large-Scale Problems

A gradient-based shape optimization methodology, that is intended for practical three-dimensional aerodynamic applications, has been developed. It is based on the quasi-analytical sensitivities. The flow analysis is rendered by a fully implicit, finite volume formulation of the Euler equations.The aerodynamic sensitivity equation is solved using the alternating-direction-implicit (ADI) algorithm for memory efficiency. A flexible wing geometry model, that is based on surface parameterization and platform schedules, is utilized. The present methodology and its components have been tested via several comparisons. Initially, the flow analysis for for a wing is compared with those obtained using an unfactored, preconditioned conjugate gradient approach (PCG), and an extensively validated CFD code. Then, the sensitivities computed with the present method have been compared with those obtained using the finite-difference and the PCG approaches. Effects of grid refinement and convergence tolerance on the analysis and shape optimization have been explored. Finally the new procedure has been demonstrated in the design of a cranked arrow wing at Mach 2.4. Despite the expected increase in the computational time, the results indicate that shape optimization, which require large numbers of grid points can be resolved with a gradient-based approach.

Pandya, Mohagna J.↗

NASA NTRS2018

Aerodynamic Shape Optimization of the STARC-ABL Concept for Minimal Inlet Distortion

The NASA single-aisle turboelectric aircraft with an aft boundary layer propulsor (STARC-ABL) concept utilizes a novel electrically driven aft fan that ingests the fuselage boundary-layer for increased propulsive efficiency. In this paper we examine how aerodynamic shaping of the fuselage diffuser and nacelle inlet can reduce the flow distortion at the aft fan. Adjoint-based aerodynamic shape optimization with the ARP1420 distortion metric objective is used to automatically determine the optimal shapes for minimal fan-face distortion. Single and multipoint optimizations are carried out for simplified body-duct and wing-body-duct configurations. These two configurations highlight the importance of including the wing downwash effects when designing the propulsor. The optimizations showed the body-duct configuration can obtain cruise distortion values of approximately 1% while the wing-body-duct configuration can obtain distortion values of just over 2%.

Kenway, Gaetan K. W.↗

DOE OSTI2023

Yet another parameter-free shape optimization method

The use of node coordinates as design variables in shape optimization offers a larger design space than computer-aided design (CAD)-based shape parameterizations. It also allows for the optimization of legacy designs, i.e., a finite element mesh from an existing design can be readily optimized to meet new performance requirements without involving a CAD model. However, it is well known that the node coordinate parameterization method is fraught with numerical difficulties, which makes it impractical to use. This has led to several of “parameter-free” shape optimization methods that seek the advantages and avoid the pitfalls of the naïve node coordinate parameterization method. These methods come in two main varieties: sensitivity filtering (or gradient smoothing) and consistent filtering. The latter is analogous to the density filter method used in topology optimization (TO). In this work, we use the PDE filter from TO and energy-based filters to implement consistent shape optimization filtering schemes easily and efficiently. Numerical experiments demonstrate that consistent methods are more robust than sensitivity filtering methods.

42 ENGINEERING↗

DOE OSTI2024

Development of a Method for Shape Optimization for a Gas Turbine Fuel Injector Design Using Metal-Additive Manufacturing

Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2004

Aerodynamic Shape Optimization Based on Free-form Deformation

This paper presents a free-form deformation technique suitable for aerodynamic shape optimization. Because the proposed technique is independent of grid topology, we can treat structured and unstructured computational fluid dynamics grids in the same manner. The proposed technique is an alternative shape parameterization technique to a trivariate volume technique. It retains the flexibility and freedom of trivariate volumes for CFD shape optimization, but it uses a bivariate surface representation. This reduces the number of design variables by an order of magnitude, and it provides much better control for surface shape changes. The proposed technique is simple, compact, and efficient. The analytical sensitivity derivatives are independent of the design variables and are easily computed for use in a gradient-based optimization. The paper includes the complete formulation and aerodynamics shape optimization results.

Samareh, Jamshid A.↗

NASA NTRS2017

Viscous Aerodynamic Shape Optimization with Installed Propulsion Effects

Aerodynamic shape optimization is demonstrated to tailor the under-track pressure signature of a conceptual low-boom supersonic aircraft. Primarily, the optimization reduces nearfield pressure waveforms induced by propulsion integration effects. For computational efficiency, gradient-based optimization is used and coupled to the discrete adjoint formulation of the Reynolds-averaged Navier Stokes equations. The engine outer nacelle, nozzle, and vertical tail fairing are axi-symmetrically parameterized, while the horizontal tail is shaped using a wing-based parameterization. Overall, 48 design variables are coupled to the geometry and used to deform the outer mold line. During the design process, an inequality drag constraint is enforced to avoid major compromise in aerodynamic performance. Linear elastic mesh morphing is used to deform volume grids between design iterations. The optimization is performed at Mach 1.6 cruise, assuming standard day altitude conditions at 51,707-ft. To reduce uncertainty, a coupled thermodynamic engine cycle model is employed that captures installed inlet performance effects on engine operation.

computational fluid dynamics↗

NASA NTRS2001

Shape Optimization of Supersonic Turbines Using Response Surface and Neural Network Methods

Turbine performance directly affects engine specific impulse, thrust-to-weight ratio, and cost in a rocket propulsion system. A global optimization framework combining the radial basis neural network (RBNN) and the polynomial-based response surface method (RSM) is constructed for shape optimization of a supersonic turbine. Based on the optimized preliminary design, shape optimization is performed for the first vane and blade of a 2-stage supersonic turbine, involving O(10) design variables. The design of experiment approach is adopted to reduce the data size needed by the optimization task. It is demonstrated that a major merit of the global optimization approach is that it enables one to adaptively revise the design space to perform multiple optimization cycles. This benefit is realized when an optimal design approaches the boundary of a pre-defined design space. Furthermore, by inspecting the influence of each design variable, one can also gain insight into the existence of multiple design choices and select the optimum design based on other factors such as stress and materials considerations.

Papila, Nilay↗

NASA NTRS2004

On Improving Efficiency of Differential Evolution for Aerodynamic Shape Optimization Applications

Differential Evolution (DE) is a simple and robust evolutionary strategy that has been proven effective in determining the global optimum for several difficult optimization problems. Although DE offers several advantages over traditional optimization approaches, its use in applications such as aerodynamic shape optimization where the objective function evaluations are computationally expensive is limited by the large number of function evaluations often required. In this paper various approaches for improving the efficiency of DE are reviewed and discussed. These approaches are implemented in a DE-based aerodynamic shape optimization method that uses a Navier-Stokes solver for the objective function evaluations. Parallelization techniques on distributed computers are used to reduce turnaround times. Results are presented for the inverse design of a turbine airfoil. The efficiency improvements achieved by the different approaches are evaluated and compared.

Madavan, Nateri K.↗

DOE OSTI2024

Shape Optimization of Header Pipes in Power Plants for Enhanced Efficiency and Environmental Sustainability

In a power plant, the header pipe plays a pivotal role in optimizing the performance of diverse systems by serving as a central conduit for the collection and distribution of steam within the plant. This paper investigates the significance of header pipes within power plant setups, highlighting their critical influence on reliability, efficiency, and the performance of the power plant as a whole. The concept of shape optimization emerges as a crucial factor in power plant design and operation, with the potential to maximize performance while minimizing the use of materials. Shape optimization not only enhances efficiency but also contributes to reducing the environmental footprint of power plant installations. In this paper, we initially developed a methodology designed for optimizing header shapes with the primary goal of reducing the usage of costly new alloy materials and lowering the overall maintenance operation expenses. Secondly, we conducted a case study based on an authentic header sourced from an operational power plant.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2004

On Improving Efficiency of Differential Evolution for Aerodynamic Shape Optimization Applications

Differential Evolution (DE) is a simple and robust evolutionary strategy that has been provEn effective in determining the global optimum for several difficult optimization problems. Although DE offers several advantages over traditional optimization approaches, its use in applications such as aerodynamic shape optimization where the objective function evaluations are computationally expensive is limited by the large number of function evaluations often required. In this paper various approaches for improving the efficiency of DE are reviewed and discussed. Several approaches that have proven effective for other evolutionary algorithms are modified and implemented in a DE-based aerodynamic shape optimization method that uses a Navier-Stokes solver for the objective function evaluations. Parallelization techniques on distributed computers are used to reduce turnaround times. Results are presented for standard test optimization problems and for the inverse design of a turbine airfoil. The efficiency improvements achieved by the different approaches are evaluated and compared.

Madavan, Nateri K.↗

NASA NTRS1993

Aerodynamic shape optimization using preconditioned conjugate gradient methods

In an effort to further improve upon the latest advancements made in aerodynamic shape optimization procedures, a systematic study is performed to examine several current solution methodologies as applied to various aspects of the optimization procedure. It is demonstrated that preconditioned conjugate gradient-like methodologies dramatically decrease the computational efforts required for such procedures. The design problem investigated is the shape optimization of the upper and lower surfaces of an initially symmetric (NACA-012) airfoil in inviscid transonic flow and at zero degree angle-of-attack. The complete surface shape is represented using a Bezier-Bernstein polynomial. The present optimization method then automatically obtains supercritical airfoil shapes over a variety of freestream Mach numbers. Furthermore, the best optimization strategy examined resulted in a factor of 8 decrease in computational time as well as a factor of 4 decrease in memory over the most efficient strategies in current use.

Burgreen, Greg W.↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions to the finite element problem, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. The transient finite-element analysis is done using TACS, and the cell-discharge battery model uses OpenMDAO and dymos. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗

DOE OSTI2020

Variable-fidelity multipoint aerodynamic shape optimization with output-based adapted meshes

This work presents a method to control the discretization error in multipoint aerodynamic shape optimization using output-based adapted meshes. The meshes are adapted via adjoint-based error estimates, taking into account both the objective and constraint output errors. A multi-fidelity optimization framework is then developed by taking advantage of the variable fidelity offered by adaptive meshes. The objective functional and its sensitivity at each design point (operating condition) are first evaluated on the same initial coarse mesh, which is then subsequently adapted for each design point individually as the shape optimization proceeds. The effort to set up the optimization is minimal since the initial mesh can be fairly coarse and easy to generate. As the shape approaches the optimal design, the mesh at each design point becomes finer, in regions necessary for that particular operating condition. The multi-fidelity framework is tightly coupled with the objective error estimation to ensure the optimization accuracy at each fidelity. Computational savings arise from a reduction of the mesh size when the design is far from optimal and avoiding an exhaustive search on low-fidelity meshes. The proposed method is demonstrated on multipoint drag minimization problems of a transonic airfoil with lift and area constraints. Improved accuracy and efficiency are shown compared to traditional fixed-fidelity optimization with a fixed computational mesh.

42 ENGINEERING↗