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Cited by 22Topology Optimization in EngineeringAdditive Manufacturing and 3D Printing TechnologiesCellular and Composite Structures

A General Framework for Designing 3D Impellers Using Topology Optimization and Additive Manufacturing

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Meli, E., Furferi, R., Rind, A., Ridolfi, A., Volpe, Y., Buonamici, F.·2020·IEEE Access
DOI 10.1109/access.2020.2982841
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Abstract

Computer Numerical Control (CNC) milling is still today the elective process for the production of single-piece impellers, as it can reliably produce complex geometries, removing the need for additional manufacturing processes. Nevertheless, Additive Manufacturing is winning more and more ground due to its ability to make components of any geometry that cannot be produced using subtractive techniques. As a result, the use of this technology can eventually be seen as the key to develop high-performance rotor components. In this scenario, the design of 3D impellers does not make an exception. Accordingly, the present paper proposes a general framework for engineered re-design and manufacture of 3D impellers installed on centrifugal compressors by exploiting Topology Optimization and Additive Manufacturing's potential. The procedure investigates also the rotoric component's best configuration for both static and dynamic behavior. Finally, the topology-optimized component is produced with AM through the use of suitable materials that can ensure efficient mechanical efficiency to prove the manufacturability of the entire procedure. To validate the proposed framework, the complete re-design of a 3D impeller of a major Italian-based Oil & Gas company is carried out, demonstrating that the re-thinking of the component in terms of Topology Optimization is a straightforward approach to increase the overall performance of the produced rotoric part.

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  • Processes such as DMLS-LPBF-SLM have demonstrated substantial weight reductions in components, achieving nearly a 30% decrease in the total mass of impellers manufactured from Inconel 718 while also optimizing operational frequencies.

    “Processes such as DMLS-LPBF-SLM have demonstrated substantial weight reductions in components, achieving nearly a 30% decrease in the total mass of impellers manufactured from Inconel 718 while also optimizing operational frequencies [69].”

    From Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing (2024) · cites this paper as [69]

    The paper’s “Static and Modal Topology Optimization” section reports that the impeller’s mass was reduced by almost 30% and frequencies around the operational range were optimized. Its materials and manufacturing sections discuss IN718 and select DMLS, but describe printing the redesigned impeller as possible rather than establishing that the nearly 30% reduction was measured in a manufactured impeller. The reported result is from topology optimization, not the manufacturing process alone. (LLM, conf=0.86)

    Experimental — accuracy not yet measured

  • 3D-printed Inconel 718 (IN718) is a strong alternative to forged components, especially considering the printable dimensions.

    “For example, a study by [69] on impeller design revealed that 3D-printed Inconel 718 (IN718) is a strong alternative to forged components, especially considering the printable dimensions.”

    From Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing (2024) · cites this paper as [69]

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Authors
Meli, E., Furferi, R., Rind, A., Ridolfi, A., Volpe, Y., & Buonamici, F.
Affiliations
University of Florence (IT)
ORCID
Venue
IEEE Access
Publisher
Institute of Electrical and Electronics Engineers (IEEE)
Published
2020
Volume
8
Pages
60259-60269
ISSN
2169-3536 (ISSN-L)
DOI
10.1109/access.2020.2982841
OpenAlex
W3013862136
Cited by
22
References
0
Citations by year
2026: 2 · 2025: 6 · 2024: 1 · 2023: 5 · 2022: 2 · 2021: 5 · 2020: 1
FWCI
1.90
Type
journal article
Language
en
Open access
Licence
Locations
  • IEEE Access (publishedVersion, cc-by)
  • Florence Research (University of Florence) (submittedVersion, cc-by)
  • DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
Funders
Baker Hughes, a General Electric company (BHGE) Nuovo Pignone
Topics
  • Physical Sciences › Engineering › Civil and Structural Engineering › Topology Optimization in Engineering
  • Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
  • Physical Sciences › Engineering › Mechanical Engineering › Cellular and Composite Structures
Keywords
topology optimization, additive manufacturing, centrifugal compressor, static and dynamic behavior, manufacturability

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