Capacity-Specific Anti-Cavitation Radial Control-Valve Trims via Density-Based Topology Optimization

We present a material distribution topology optimization (TO) framework that directly generates capacity-specific radial trims for severe-service control valves. The method uses an out-of-plane resistance modified two-dimensional turbulence model and objective functions that maximize directional change to create tortuous pressure-staging geometries at predefined channel depths. Four trims targeting non-dimensional capacities (CV) of 0.672, 0.96 (two objectives), and 1.248 were optimized, MSLA-printed, and tested in a globe valve using IEC 60534 procedures. The measured capacities ranged from −13.7% to +4.8% of the targets for a fully 2D optimization process, dropping to a maximum of 7.8% when coupled with a hybrid 3D tuning step. Acoustic detection indicated incipient cavitation at a pressure drop ratios greater than 0.87 for the most highly staged design and 0.73 for the highest capacity design, which is consistent with our simulations of the flow field before fabrication. These results demonstrate that TO can deliver fit-to-service, capacity-tuned trims with excellent cavitation suppression, reducing reliance on large parametric design libraries.