Robust design optimisation of gas turbine compression systems

Engineering design commonly assumes nominal values for uncertain parameters to simplify the design process: the design of a gas turbine, or one of its modules, is generally approached with some specific operating conditions in mind (its design point). Unfortunately, engine components never exactly meet their specifications and do not operate at just one condition, but over a range of power settings. This simplification can then lead to a product that exhibits performance significantly worse than nominal in real-world conditions. This problem is exacerbated in the presence of heavily optimised designs, which tend to lie in extreme regions of the design space.¹⁵ In gas turbine design, safe and satisfactory off-design operation must be guaranteed and is generally evaluated before moving to the next phase of the design process. This approach, while guaranteeing that some minimum requirements are met, introduces a further loop in the design process and does not ensure the final design will be optimal with respect to this new requirement. The introduction of some robustness considerations into the design process can reduce the level of fragmentation and iteration typical of gas turbine engine design and produce further (and more robust) improvements relative to the traditional method. In this study, two approaches for dealing with off-design performance analysis are presented, integrated into an automatic optimisation system and applied to the preliminary design of a core compression system from a three-spool modern turbofan engine. Designs that are more robust than those found if only design-point performance is considered are successfully identified.