Composite design of aero-engine components based on surrogate model
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摘要:
结构复材化是航空发动机提高推质比的重要途径。针对反推叶栅复材化设计中，叶栅中各结构铺层方案设计因铺层角度和铺层顺序多变，难以确定最优铺层方案的问题，展开复合材料反推叶栅设计。采用遗传算法设计样本点，并对不同铺层方案的复合材料结构进行有限元分析，分析其变形、强度及刚度。其次建立代理模型，以反推叶栅中各特征结构工况载荷下变形、强度及刚度为目标，优化后对不同铺层方案进行有限元分析，综合对比得到最优铺层方案。以反推叶栅中各结构最优铺层方案为优化结果建立复合材料反推叶栅模型，并与铝合金反推叶栅的变形、强度及刚度进行对比，结果表明与铝合金反推叶栅差距仅为11%左右。验证了所选混合铺层反推叶栅的优越性。
Abstract:Composite design is an important way to improve the thrust to weight ratio of aero-engines. However, due to the variability in lay-up angles and sequences, it is difficult to determine the optimal lay-up scheme for each structure in the cascade. Therefore, the design of composite material reverse thrust cascades was carried out. The sample points were designed by genetic algorithm, and finite element analysis of composite structures with different lay-up schemes was performed. The surrogate model was established, the deformation, strength and stiffness under the working load of each characteristic structure in the reverse thrust cascade were taken as the targets, and finite element analysis was carried out for different lay-up schemes after optimization, and the optimal lay-up scheme was obtained by comprehensive comparison. The composite reverse thrust cascade models were modeled according to the optimal lay-up scheme and compared with the aluminum alloy reverse thrust cascade model. Result showed that the gap with the aluminum alloy cascades was only about 11%, verifying the superiority of the selected mixed lay-up scheme.
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Key words:
- composite /
- reverse thrust cascade /
- lay-up angle /
- lay-up sequence /
- surrogate model /
- lay-up scheme
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图 2 反推叶栅中各特征结构划分
Figure 2. Division of characteristic structures in the reverse thrust cascades
图 3 反推叶栅中5类结构代表模型
Figure 3. Representative model of five types in the reverse thrust cascade
图 4 不同反推叶栅正常工况下最大位移及最大主应力对比
Figure 4. Comparison of maximum displacement and maximum principal stress of different reverse thrust cascades under normal working load
表 1 各结构受载下最大位移及最大主应力
Table 1. Maximum displacement and maximum principal stress of each structure under load
区域 最大位移/mm 最大主应力/MPa A 3.97×10−1 2.14×101 B 3.26×10−4 3.34×10−1 C 1.08×10−1 8.96 D 5.19×10−2 6.59 E 1.58×10−1 1.27×101 
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表 2 各结构单向带铺设铺层方案
Table 2. Unidirectional composite lay-up scheme of each structure
区域 铺层方案 A $ {\left[45/0/{-45}_{4}/\overline {0}\right]}_{{\mathrm{s}}} $ B $ {\left[{45}_{2}/-45/45/{-45}_{2}/{90/45}_{2}/{-45}_{2}/0/90\right]}_{{\mathrm{s}}} $ C $ {\left[0/45/0/45/-45/0/{-45}_{2}/0\right]}_{{\mathrm{s}}} $ D $ {\left[-45/90/{0}_{2}/-45/45/-45/{0}_{4}/\overline {0}\right]}_{{\mathrm{s}}} $ E $ {\left[{45}_{2}/0/-45/0/-45/45/-45/\overline {90}\right]}_{{\mathrm{s}}} $
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表 3 各结构平纹织物铺设铺层方案
Table 3. Plain weave fabric lay-up scheme of each structure
区域 铺层方案 A $ {\left[{ （+/-45） }_{2}/{ （\mathrm{0,90}） }_{2}/{ （+/-45） }_{2}/\overline { （+/-45） }\right]}_{{\mathrm{s}}} $ B $ {\left[ （\mathrm{0,90}） /{ （+/-45） }_{4}/{ （\mathrm{0,90}） }_{4}/ （+/-45） /{ （\mathrm{0,90}） }_{2}/\overline { （+/-45） }\right]}_{{\mathrm{s}}} $ C $ {\left[ （+/-45） /{ （\mathrm{0,90}） }_{3}/ （+/-45） /{ （\mathrm{0,90}） }_{2}/{ （+/-45） }_{2}\right]}_{{\mathrm{s}}} $ D $ {\left[{ （\mathrm{0,90}） }_{4}/{ （+/-45） }_{7}/\overline { （+/-45） }\right]}_{{\mathrm{s}}} $ E $ {\left[ （+/-45） / （\mathrm{0,90}） /{ （+/-45） }_{4}/ （\mathrm{0,90}） / （+/-45） /\overline { （\mathrm{0,90}） }\right]}_{{\mathrm{s}}} $
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表 4 各结构斜纹织物铺设铺层方案
Table 4. Twill weave fabric lay-up scheme of each structure
区域 铺层方案 A $ {\left[{ （+/-45） }_{2}/ （\mathrm{0,90}） /{ （+/-45） }_{2}/ （\mathrm{0,90}） /\overline { （+/-45） }\right]}_{{\mathrm{s}}} $ B $ {\left[{ （\mathrm{0,90}） }_{2}/{ （+/-45） }_{5}/ （\mathrm{0,90}） / （+/-45） /{ （\mathrm{0,90}） }_{2}/ （+/-45） / （\mathrm{0,90}） \right]}_{{\mathrm{s}}} $ C $ {\left[{ （+/-45）/ （\mathrm{0,90}） }_{7}/（+/-45）\right]}_{{\mathrm{s}}} $ D $ {\left[ （\mathrm{0,90}） /（+/-45）/{ （\mathrm{0,90}） }_{7}/（+/-45）/ （\mathrm{0,90}） /\overline { （\mathrm{0,90}） }\right]}_{{\mathrm{s}}} $ E $ {\left[ （+/-45） / （\mathrm{0,90}） /{ （+/-45） }_{5}/ （\mathrm{0,90}） /\overline { （+/-45） }\right]}_{{\mathrm{s}}} $
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表 5 各结构单向带和平纹织物混合铺设铺层方案
Table 5. Unidirectional composite and plain weave fabric mixed lay-up scheme of each structure
区域 铺层方案 A $ {\left[ （+/-45） /0/{ （+/-45） }_{2}/0/ （\mathrm{0,90}） /\overline {0}\right]}_{{\mathrm{s}}} $ B $ {\left[ （+/-45） /-45/ （\mathrm{0,90}） /45/90/ （\mathrm{0,90}） /0/45/{ （+/-45） }_{2}/45/ （\mathrm{0,90}） / （+/-45） \right]}_{{\mathrm{s}}} $ C $ {\left[{ （\mathrm{0,90}） }_{2}/ （+/-45） /0/ （+/-45） /0/{ （+/-45） }_{2}/ （\mathrm{0,90}） \right]}_{{\mathrm{s}}} $ D $ {\left[{0}_{2}/-45/ （+/-45） /0/-45/ （\mathrm{0,90}） /0/ （+/-45） /{ （\mathrm{0,90}） }_{2}/\overline { （\mathrm{0,90}） }\right]}_{{\mathrm{s}}} $ E $ {\left[ （+/-45） / （\mathrm{0,90}） /{45}_{2}/{ （\mathrm{0,90}） }_{2}/ （+/-45） /45/\overline {0}\right]}_{{\mathrm{s}}} $
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表 6 不同材料反推叶栅正常工况载荷下最大位移及最大主应力
Table 6. Maximum displacement and maximum principal stress of reverse thrust cascades made of different materials under normal working load
材料 最大位移/mm 最大主应力/MPa 铝合金 4.79×10−1 8.21×101 单向带 4.90×10−1 1.18×102 平纹 7.91×10−1 1.12×102 斜纹 1.24 1.17×102 混合 5.34×10−1 9.11×101 实际 1.01 1.01×102
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表 7 复合材料反推叶栅相对于铝合金叶栅在工况下差距
Table 7. Difference between composite reverse thrust cascades and aluminum alloy cascades under working load
% 材料 最大位移 最大主应力 单向带 2.30 44.18 平纹 65.14 35.89 斜纹 158.87 42.72 混合 11.48 11.04 实际 110.86 22.97
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