Integrated through-flow and CFD optimization design method of multi-stage compressors

Through-flow and computational fluid dynamics (CFD) calculations are the main approaches used for aerodynamic design and analyses of turbomachinery. In this study, an integrated through-flow and CFD optimization design method using an in-house through-flow code was used to analyze highly loaded multi-stage axial compressors. This method uses a multi-level aerodynamic analysis process that combines the through-flow and CFD calculations in a design optimization process that combines 3D blade design and intelligent optimization algorithms. The method is applied to a 3-stage transonic compressor and reasonably categorizes the flow problems resulting from the boundary layer separation along the transonic rotors. The analysis is used to optimize the first rotor (R1) and third rotor (R3) designs with the optimized designs giving 0.1 percent point and 0.3 percent point increases in the efficiencies of the 3-stage compressor. This study shows that this method is capable of synthesizing the advantages of the through-flow and CFD methods to simultaneously consider the characteristics of the aerodynamic configuration and flow structures. The compressor flow fields and performance can be efficiently categorized based on their relationships to the blade profile and aerodynamic configurations to provide guidance on how to optimize the design. © 2022, Tsinghua University Press. All right reserved.