Topology and shape optimization of twin-web turbine disk

Turbine disk is a key bearing component in aero-engine, and its structural design directly affects the overall performance of the engine. This work presents a cascade optimization method combining topology optimization (TOP) with shape optimization to design a high-performance twin-web turbine disk. A bi-directional evolutionary structural optimization (BESO-TOP) incorporated with random sampling sensitivity analysis strategy (RSSA) was firstly established, and the meridian surface configuration of turbine disk was designed using the RSSA-BESO-TOP. Afterward, the NURBS-spline was used to fit the obtained topological boundaries of turbine disk, and the shape optimization was subsequently carried out. Result shows that fourteen constraints regarding stress, deformation, and fatigue life for the optimal twin-web turbine disk completely meet the design requirements of aero-engine turbine disk. In contrast to the reference single-web turbine disk, the overall weight of twin-web turbine disk is reduced by 21.35% and the strain energy is improved by 8.5%, indicating that the twin-web turbine disk is generally evolving toward a fully stressed structure. Ultimately, the prototype of the optimal twin-web turbine disk was printed using 3D printing, and the DIC tests were performed to compare the mechanical responses of twin-web and single-web turbine disks.