Automatic optimization techniques have been used in recent years to facilitate more rapid analyses of different design options with multiple performance objectives. Typically, this process has been used during new product development. In this paper, a design system is presented, which enables the multipoint, multi-objective optimization of the centrifugal compressor stage aerodynamic components. Moreover, it is applied to a design modification of a multistage compressor, during the manufacturing cycle, for risk mitigation. The system is based on the application of the Isight code for coupling of one dimensional direct design and analysis with multi-objective genetic algorithms, design of experiment, and response surface method. The design system was applied to a redesign of the diffuser, crossover, and return channel of two stages in a multistage compressor. The geometry parameterization is performed by a one dimensional analysis method where the diffuser width, crossover inlet and exit width and associated inner and outer radii, are used to describe the meridional flow path while holding the return vane geometry unchanged. Centrifugal compressor performance parameters, such as polytropic head and efficiency at the client rated point, head rise to surge, and choke flow capacity are evaluated during the optimization process. The example confirmed the validity of the system to perform the optimization of turbomachine components in a time efficient manner to meet production schedule. The system also allowed for a sensitivity analysis of the impact of geometry parameters on the aerodynamic performance, contributing to the development of guidelines for manufacturers to design new products and mitigate the performance risk on test floor.

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