Additive Bearing Housing Assembly for Gas Turbine Engines
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Solution Overview
Problem
Manufacturing gas turbine engine bearing housings that meet stringent performance, safety, and reliability requirements in harsh temperature environments and under stress and vibrational conditions is challenging due to their complex structure and the inefficiencies of traditional manufacturing methods.
Innovation Solution
The method involves producing segments of the bearing housing using additive manufacturing processes, particularly for the intermediate structure segment, and attaching these segments via weldments to form a complete annular bearing housing, which includes features like engine oil conduits and plenums, enhancing mechanical properties through rib and lattice structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for bearing housings, then manufacturing complexity is reduced, but production time and costs increase
Solution Approach 1:
The bearing housing is divided into multiple segments (first segment, second segment, third segment) that can be manufactured separately using additive manufacturing and then assembled together. This segmentation allows parallel production of multiple components, reducing overall production time while managing complexity through modular construction.
Solution Approach 2:
The patent applies additive manufacturing parameters to create complex geometries that would be difficult or impossible to achieve with traditional manufacturing. By changing the manufacturing approach to additive processes, the patent can produce intricate internal structures, optimized stress distributions, and complex external geometries directly, reducing production time despite increased digital modeling complexity.
2Productivity
If traditional manufacturing methods are used for bearing housings, then manufacturing simplicity is maintained, but costs increase
Solution Approach 1:
Dividing the bearing housing into manufacturable segments enables cost-effective additive manufacturing of complex features in each segment. The modular approach allows for optimized material usage, reduced support structures, and simplified post-processing for each individual segment, lowering overall production costs despite requiring multiple assembly operations.
Solution Approach 2:
The patent combines multiple bearing housing segments with integrated features (such as integrated cooling channels, mounting features, and structural elements) into a single additive manufacturing process for each segment. This merging of features reduces the need for separate machining operations, fasteners, and assembly steps, thereby reducing costs while maintaining manufacturing feasibility.
3Strength
If segments are attached via weldments, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The bearing housing is segmented to allow additive manufacturing of each portion with optimized structural features. The segments are designed with integrated attachment features and reinforcement elements that facilitate weldment assembly. This segmentation maintains structural integrity through proper joint design while enabling parallel manufacturing of segments, reducing overall production time.
Data Source
AI summary
A method of manufacturing an annular bearing housing for a gas turbine engine is provided that includes: producing a flange outer structure segment; producing an intermediate structure segment having an outer radial end, an inner radial end, a body that extends between the outer radial end and the inner radial end, and a branch member that extends outwardly from the body; producing a main body segment; attaching the flange outer structure segment to the outer radial end of the intermediate structure segment; and attaching the main body segment to the inner radial end of the intermediate structure segment. At least one of the flange outer structure segment, the intermediate structure segment, or the main body segment is produced using an additive manufacturing process.