Analysis of the possibility of using topology optimization in the design of uncooled turbine rotor blades

This paper discusses a novel approach of gas turbine rotor blade design in order to take full advantage of rapidly developing additive manufacturing. It is necessary to implement new numerical optimization methods, such as topology optimization, in the design process in order to reduce weight by eliminating unnecessary material. As an example, topology optimization is conducted to find the optimal geometry of typical low-pressure turbine uncooled blade to ensure meeting the requirement of tuning out from the resonance frequencies of vibrations and obtaining minimum mass. As a result of optimization, potential weight reduction of 30% is obtained, while maintaining the blade profile. The check calculation results show the sufficiency of the safety margin values of the resulting blade design. In addition, the paper provides a description of the technological constraints of additive manufacturing and describes a possible method of the resulting blade manufacturing. The results indicate a potential of using topology optimization in the design of uncooled turbine rotor blades with regard to additive manufacturing in order to reduce weight and control natural vibration frequencies. The symbiosis of additive manufacturing and topology optimization will make it possible to use the full potential of both technologies.