考虑增材制造各向异性的发动机盘类件结构拓扑优化

  • 张立章 ,
  • 郭浩为 ,
  • 陈欢欢 ,
  • 赵艳云 ,
  • 艾书民 ,
  • 杨新龙 ,
  • 闫成
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  • 1. 中航工业航空动力机械研究所
    2. 厦门大学航空航天学院
    3. 中国航发湖南动力机械研究所
    4. 厦门大学

收稿日期: 2026-03-04

  修回日期: 2026-05-18

  网络出版日期: 2026-05-21

基金资助

国家自然科学基金;中国航发自主创新专项基金;福建省自然科学基金;中央高校基本科研业务费

Topology optimization of aero-engine disks considering additive manufacturing-induced anisotropy

  • ZHANG Li-Zhang ,
  • GUO Hao-Wei ,
  • CHEN Huan-Huan ,
  • ZHAO Yan-Yun ,
  • AI Shu-Min ,
  • YANG Xin-Long ,
  • YAN Cheng
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Received date: 2026-03-04

  Revised date: 2026-05-18

  Online published: 2026-05-21

摘要

盘类件在航空发动机中应用广泛,其性能优化是提升发动机性能的关键环节。增材制造技术凭借高加工自由度显著拓展了此类结构的设计空间,但其固有的逐层堆积特性使构件沿打印方向呈现显著的各向异性,给结构设计带来挑战。为此,提出了一种考虑增材制造各向异性的航空发动机盘类件结构拓扑优化方法。首先,针对盘类件特性,建立了适用于轴对称结构的各向异性材料模型,为拓扑优化中的各向异性材料属性插值与结构优化奠定理论基础。其次,实现了 Tsai-Wu 强度准则在轴对称各向异性结构中的数值离散,可有效预测打印件的各向异性强度分布,并反映沿打印方向的结构拉压不对称特性。接着,构建了以质量最小化为目标、各向异性强度为约束的拓扑优化模型,并基于伴随法推导了目标函数及约束的灵敏度。最后,通过对称压气机盘、非对称涡轮盘和涡轮后挡板盘三个案例验证了所提方法的有效性。与基于von Mises准则的传统设计相比,本方法在保证结构安全的前提下,可实现质量降幅20%以上,显著提升了轻量化效果与设计可靠性,为增材制造轴对称结构的安全轻量化设计提供了有效途径。

本文引用格式

张立章 , 郭浩为 , 陈欢欢 , 赵艳云 , 艾书民 , 杨新龙 , 闫成 . 考虑增材制造各向异性的发动机盘类件结构拓扑优化[J]. 航空学报, 0 : 1 -0 . DOI: 10.7527/S1000-6893.2026.33532

Abstract

Disk-type components are widely used in aero-engines, and their performance optimization is a key factor in enhancing overall engine performance. Additive manufacturing technology significantly expands the design space for such structures due to its high degree of processing freedom. However, its inherent layer-by-layer deposition characteristic results in significant anisotropy along the printing direction, posing challenges for structural design. To address this, a topology optimization method for aero-engine disk-type components that accounts for additive manufacturing-induced anisotropy is proposed. First, considering the features of disk-type components, an anisotropic material model suitable for axisymmetric structures is established, providing a theoretical foundation for material property interpolation and structural optimization. Second, the numerical discretization of the Tsai-Wu strength criterion for anisotropic axisymmetric structures is implemented, which can effectively predict the anisotropic strength distribution of printed parts and reflect the tensile-compressive asymmetry along the printing direction. Next, a topology optimization model is constructed with the objective of minimizing mass and the constraint of anisotropic strength. The sensitivities of the objective function and constraints are derived based on the adjoint method. Finally, the effectiveness of the proposed method is validated through three case studies: a symmetric compressor disk, an asymmetric turbine disk, and a turbine rear cooling plate. Compared with traditional designs based on the von Mises criterion, the proposed method achieves a mass reduction of over 20% while ensuring structural safety, significantly improving lightweight performance and design reliability. This provides an effective approach for the safe and lightweight design of additively manufactured axisymmetric structures.
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