HCF Weak Link Optimization for Wide-Chord Fan Blades Based on Circumferential Stacking Line Design

This paper describes the combination of a Kriging surrogate model with a micro-genetic algorithm for studying the influence of circumferential perturbations from the stack line on the high-cycle fatigue (HCF) weak link of a fan blade in a high-bypass-ratio turbofan engine. Based on the circumferential perturbations of the fan blade stack line, an automated system is developed for the parameterized modeling and meshing of the blade, and an integral platform is established for parameterized modeling, finite-element simulation, and optimization. The static stress, index of strain energy density, and vibratory stress margin of the 1st flex mode are set as the objective functions for the optimization of a fan blade. The results show that the optimized blade has three areas of low static stress, unlike the single "bull's eye" distribution of the baseline blade. Optimization reduces the maximum static stress by 5.87% and the strain energy density index by 0.77%, while increasing the vibratory stress margin under the same dynamic load by 9.51%. The natural frequencies, mode shapes, resonance margins, and aerodynamic parameters exhibit no significant changes, which illustrates that the optimization method can improve the static stress and vibratory stress distribution of the fan blade without negatively influencing the other vibration and aerodynamic characteristics. The proposed method is an effective means of fan blade design optimization, and could be applied alongside other design variables and objective functions, such as the swept and skewed configuration of the stack line and twist angle of the blade, to optimize the vibration characteristics and aero-elastic performance.