Design Optimization of a Transonic-Fan Rotor Using Numerical Computations of the Full Compressible Navier-Stokes Equations and Simplex Algorithm

The design of a transonic-fan rotor is optimized using numerical computations of the full three-dimensional Navier-Stokes equations. The CFDRC-ACE multiphysics module, which is a pressure-based solver, is used for the numerical simulation. The code is coupled with simplex optimization algorithm. The optimization process is started from a suitable design point obtained using low fidelity analytical methods that is based on experimental correlations for the pressure losses and blade deviation angle. The fan blade shape is defined by its stacking line and airfoil shape which are considered the optimization parameters. The stacking line is defined by lean, sweep, and skews, while blade airfoil shape is modified considering the thickness and camber distributions. Theoptimization has been performed tomaximize the rotor total pressure ratio while keeping the rotor efficiency and surgemargin above certain required values. The results obtained are verified with the experimental data of Rotor 67. In addition, the results of the optimized fan indicate that the optimum design is found to be leaned in the direction of rotation and has a forward sweep from the hub to mean section and backward sweep to the tip. The pressure ratio increases from 1.427 to 1.627 at the design speed and mass flow rate.