Optimized design of deformation adaptation for thermoplastic composite wound multi-ring rotors

Abstract

This article presents a novel optimization framework that combines parametric modeling with the Whale Optimization Algorithm (WOA) enhanced by hybrid strategies, improving the design efficiency of thermoplastic composite wound multi-ring rotors. The challenges associated with optimization and design complexities of the optimization framework are clarified by creating mechanical models for both the winding and rotating stages while incorporating the characteristics of the thermoplastic winding process. To attain the intended deformation of the composite multi-ring rotors at elevated rotational speeds, a detailed parametric finite element model has been created utilizing birth and death unit technology. A hybrid strategy, WOA, is proposed to address the challenges of multivariable optimization while considering both strength and deformation constraints and the difficulty of aligning with the parametric model. In conclusion, some strategies were assessed during the optimization process, leading to the design of a 100,000 r/min rotor cover. A feasibility study of the laser-assisted thermoplastic composite winding process was conducted through material property evaluation, process control, and monitoring of key indicators, preliminarily demonstrating the applicability of the proposed method. This study provides valuable insights into the design and manufacturing of thermoplastic composite wound multi-ring rotors and highlights their potential in high-speed rotating part applications.