Multi-objective optimization design of a centrifugal impeller considering both aerodynamic efficiency and structural machinability

Purpose This study aims to complete the optimization design of a centrifugal impeller with both high aerodynamic efficiency and good structural machinability. Design/methodology/approach First, the design parameters were derived from the blade loading distribution and the meridional geometry in the impeller three-dimensional (3D) inverse design. The blade wrap angle at the middle span surface and the spanwise averaged blade angle at the blade leading edge obtained from inverse design were chosen as the machinability objectives. The aerodynamic efficiency obtained by computational fluid dynamics was selected as the aerodynamic performance objective. Then, using multi-objective optimization with the optimal Latin hypercube method, quadratic response surface methodology and the non-dominated sorting genetic algorithm, the trade-off optimum impellers with small blade wrap angles, large blade angles and high aerodynamic efficiency were obtained. Finally, computational fluid dynamics and computer-aided manufacturing were performed to verify the aerodynamic performance and structural machinability of the optimum impellers. Findings Providing the fore maximum blade loading distribution at both the hub and shroud for the 3D inverse design helped to promote the structural machinability of the designed impeller. A straighter hub coupled with a more curved shroud also facilitated improvement of the impeller's structural machinability. The preferred impeller was designed by providing both the fore maximum blade loading distribution at a relatively straight hub and a curved shroud for 3D inverse design. Originality/value The machining difficulties of the designed high-efficiency impeller can be reduced by reducing blade wrap angle and enlarging blade angle at the beginning of impeller design. It is of practical value in engineering by avoiding the follow-up failure for the machining of the designed impeller.