Multi-scale design and optimization for solid-lattice hybrid structures and their application to aerospace vehicle components

By integrating topology optimization and lattice-based optimization, a novel multi-scale design method is proposed to create solid-lattice hybrid structures and thus to improve the mechanical performance as well as reduce the structural weight. To achieve this purpose, a two-step procedure is developed to design and optimize the innovative structures. Initially, the classical topology optimization is utilized to find the optimal material layout and primary load carrying paths. Afterwards, the solid-lattice hybrid structures are reconstructed using the finite element mesh based modeling method. And lattice-based optimization is performed to obtain the optimal cross-section area of the lattice structures. Finally, two typical aerospace structures are optimized to demonstrate the effectiveness of the proposed optimization framework. The numerical results are quite encouraging since the solid-lattice hybrid structures obtained by the presented approach show remarkably improved performance when compared with traditional designs.     

Applications of structural efficiency assessment method on structural-mechanical characteristics integrated design in aero-engines

In the design process of advanced aero-engines, it is necessary to carry out an effective analysis method between structural features and mechanical characteristics for a better structural optimization. Based on the structural composition and functions of aero-engines, the concept and contents of structural efficiency can reflect the relation between structural features and mechanical characteristics. In order to achieve the integrated design of structural and mechanical characteristics, one quantitative analysis method called Structural Efficiency Assessment Method (SEAM) was put forward. The structural efficiency coefficient was obtained by synthesizing the parameters to quantitatively evaluate the aero-engine structure design level. Parameterization method to evaluate structural design quality was realized. After analyzing the structural features of an actual dual-rotor system in typical high bypass ratio turbofan engines, the mechanical characteristics and structural efficiency coefficient were calculated. Structural efficiency coefficient of high-pressure rotor (0.43) is higher than that of low-pressure rotor (0.29), which directly shows the performance of the former is better, there is room for improvement in structural design of the low-pressure rotor. Thus the direction of structural optimization was pointed out. The applications of SEAM shows that the method is operational and effective in the evaluation and improvement of structural design.     

Inverse identification of constitutive parameters of Ti2AlNb intermetallic alloys based on cooperative particle swarm optimization

Ti₂AlNb intermetallic alloy is a relatively newly developed high-temperature-resistant structural material, which is expected to replace nickel-based super alloys for thermally and mechanically stressed components in aeronautic and automotive engines due to its excellent mechanical properties and high strength retention at elevated temperature. The aim of this work is to present a fast and reliable methodology of inverse identification of constitutive model parameters directly from cutting experiments. FE-machining simulations implemented with a modified Johnson-Cook (TANH) constitutive model are performed to establish the robust link between observables and constitutive parameters. A series of orthogonal cutting experiments with varied cutting parameters is carried out to allow an exact comparison to the 2D FE-simulations. A cooperative particle swarm optimization algorithm is developed and implemented into the Matlab programs to identify the enormous constitutive parameters. Results show that the simulation observables (i.e., cutting forces, chip morphologies, cutting temperature) implemented with the identified optimal material constants have high consistency with those obtained from experiments, which illustrates that the FE-machining models using the identified parameters obtained from the proposed methodology could be predicted in a close agreement to the experiments. Considering the wide range of the applied unknown parameters number, the proposed inverse methodology of identifying constitutive equations shows excellent prospect, and it can be used for other newly developed metal materials.     

A novel framework for liquid propellant engine’s cooling system design by sensitivity analysis based on RSM and multi-objective optimization using PSO

One of the challenges of combustion chamber and nozzle design in a Liquid Propellant Engine (LPE) is to predict the behavior and performance of the cooling system. Therefore, while designing, the optimization of the cooling system is always of great importance. This paper presents the multi-objective optimization of the LPE’s cooling system. To this end, a novel framework has been developed, resulting from the application of the Response Surface Method (RSM) and the correlation coefficients matrix, sensitivity analysis and the The Particle Swarm Optimization (PSO). based on this method, the input variables, constraints, objective functions, and their surfaces were identified. In terms of multi-optimization algorithms, RSM and PSO are utilized to get global optimum. In conclusion, the methodology capability is to optimize the LPE’s cooling system, 6 percentage increase in total heat transfer and 7 bar decrease cooling system pressure loss, which resulted in a 1.2-seconds increase in the specific impulse of the engine.     

Formation flying reconfiguration manoeuvres via environmental forces in highly elliptical orbits

A study on reconfiguration manoevres applied to a tetrahedral formation in highly elliptical orbits is proposed, by using a propellantless solution. The manoeuvring strategy consists in exploiting certain environmental forces, specifically those provided by solar radiation pressure and atmospheric drag, by actively controlling the satellites’ attitudes. Through inverse dynamics particle swarm optimization the optimal attitudes required for the manoeuvres are evaluated, whereas the configuration’s evolution is simulated by a high-fidelity orbital simulator. The goal of the reconfiguration problem is to find an optimal control in order for the four spacecraft to reach a desired configuration in a specified portion of orbit, where the desired configuration is evaluated by a shape and size geometric parameter. By increasing the manoeuvring time and the satellites’ area to mass ratio, all the case studies considered are successfully verified.     

Multiscale topology optimization using feature-driven method

This paper presents a multiscale design method for simultaneous topology optimization of both macrostructures and microstructures. Geometric features are extended as design primitives at both macro and micro scales and represented by Level Set Functions (LSFs). Parameters related to the locations, sizes, and orientations of macro and micro features are considered as design variables and optimized simultaneously. In the overlapping areas of different macro features, embedded microstructures are optimally figured out as the solution of the corresponding sub-optimization problem. In this study, the eXtended Finite Element Method (XFEM) is implemented for structural and sensitivity analyses with respect to design variables. This method has the advantage of using a fixed grid independent of the topology optimization process. The homogenization procedure is applied to calculate the effective properties of considered microstructures in each macro feature. Numerical examples are presented to illustrate the effectiveness of the proposed method. Results depict that the multiscale design cannot obviously improve structural stiffness compared with a solid-material design under the linear elastic condition.     

Application of a PCA-DBN-based surrogate model to robust aerodynamic design optimization

An efficient method employing a Principal Component Analysis (PCA)-Deep Belief Network (DBN)-based surrogate model is developed for robust aerodynamic design optimization in this study. In order to reduce the number of design variables for aerodynamic optimizations, the PCA technique is implemented to the geometric parameters obtained by parameterization method. For the purpose of predicting aerodynamic parameters, the DBN model is established with the reduced design variables as input and the aerodynamic parameters as output, and it is trained using the k-step contrastive divergence algorithm. The established PCA-DBN-based surrogate model is validated through predicting lift-to-drag ratios of a set of airfoils, and the results indicate that the PCA-DBN-based surrogate model is reliable and obtains more accurate predictions than three other surrogate models. Then the efficient optimization method is established by embedding the PCA-DBN-based surrogate model into an improved Particle Swarm Optimization (PSO) framework, and applied to the robust aerodynamic design optimizations of Natural Laminar Flow (NLF) airfoil and transonic wing. The optimization results indicate that the PCA-DBN-based surrogate model works very well as a prediction model in the robust optimization processes of both NLF airfoil and transonic wing. By employing the PCA-DBN-based surrogate model, the developed efficient method improves the optimization efficiency obviously.     

基于多可信度代理模型的尾喷管优化设计

尾喷管是飞行器机体/推进一体化设计中的关键部件之一,直接影响着飞行器的推阻匹配、俯仰力矩配平等特性。为了提高尾喷管优化设计效率,建立基于多可信度代理模型的多目标优化模型。以基于粗网格、无黏模型的CFD 结果作为低可信度数据,以基于细密网格、SST k-ω 湍流模型的CFD 结果作为高可信度数据,将最大化推力系数、升力系数和俯仰力矩系数作为优化目标,构建Cokriging 模型,并结合NSGA-Ⅱ算法得到Pareto 解集。结果表明：以上三个目标分别提升了2.94%、13.0% 和40.6%,误差低于0.5%,并进行了敏感性分析;优化后流场波系结构更为复杂,改变了壁面压强分布规律;与Kriging 模型相比,Cokriging 模型具有相当的预测性能,构建时间成本节省了62%。     

一种基于语义信息辅助的无人机视觉/惯性融合定位方法CSCD

视觉传感器在无人机室内定位中发挥着重要作用。传统基于特征点的视觉里程计算法通过底层亮度关系进行描述匹配,抗干扰能力不足,会出现匹配错误甚至失败的情况,导航系统的精度及鲁棒性有待提升。由于室内环境存在丰富的语义信息,提出了一种基于语义信息辅助的无人机视觉/惯性融合定位方法。首先,将室内语义信息进行因子建模,并与传统的视觉里程计方法进行融合;然后,基于惯性预积分方法,在因子图优化中添加惯性约束,以进一步提高无人机在动态复杂环境下的定位精度和鲁棒性;最后,通过无人机室内飞行试验对算法的定位精度进行了分析。试验结果表明,相较于传统的视觉里程计算法,该方法具有更高的精度和鲁棒性。     

一种基于随机优化算法的民用飞机突风动载荷重建方法

民用飞机突风载荷的准确重建对于飞行安全具有十分重要的意义。基于随机优化算法,提出一种突风动载荷重建方法。首先,基于频域气弹耦合方程,建立一个突风动载荷时域分析模型,其次,引入Hicks-Henne 型函数进行突风速度场的参数化建模,在此基础上,基于随机优化算法对各型函数参数进行迭代寻优,使得优化目标值与测量值一致,最终得到重建后的突风速度及对应的动态响应及载荷。最后,以GTA 模型经历1-cos 形状突风为例进行数值仿真。结果表明：本文提出的突风动载荷重建方法可有效实现突风速度场的识别,进而完成突风动载荷的重建;针对本文算例,过载最大误差为3.5%,载荷最大误差不超过1%。