Development of a 3D CFD aerodynamic optimization tool and application to engine air intake design

Abstract

PurposeThe paper deals with research activities to develop optimization workflows implying computational fluid dynamics (CFD) modelling. The purpose of this paper is to present an industrial and fully-automated optimal design tool, able to handle objectives, constraints, multi-parameters and multi-points optimization on a given CATIA CAD. The work is realized on Rapid And CostEffective Rotorcraft compound rotorcraft in the framework of the Fast RotorCraft Innovative Aircraft Demonstrator Platform (IADP) within the Clean Sky 2 programme.Design/methodology/approachThe proposed solution relies on an automated CAD-CFD workflow called through the optimization process based on surrogate-based optimization (SBO) techniques. The SBO workflow has been specifically developed.FindingsThe methodology is validated on a simple configuration (bended pipe with two parameters). Then, the process is applied on a full compound rotorcraft to minimize the flow distortion at the engine entry. The design of the experiment and the optimization loop act on seven design parameters of the air inlet and for each individual the evaluation is performed on two operation points, namely, cruise flight and hover case. Finally, the best design is analyzed and aerodynamic performances are compared with the initial design.Originality/valueThe adding value of the developed process is to deal with geometric integration conflicts addressed through a specific CAD module and the implementation of a penalty function method to manage the unsuccessful evaluation of any individual.