Additive Fuel Ring Integrated with Engine Case
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Solution Overview
Problem
Conventional fluid dispensing systems in attritable aircraft engines are complex, costly, time-consuming to manufacture, and heavy, requiring numerous parts that are difficult to maintain and package, necessitating a simpler and more robust design.
Innovation Solution
An additively manufactured attritable engine with an integrated fuel dispensing system, featuring a fuel ring integral to the engine case and a fuel manifold, along with a fuel injector, reduces the number of parts and leverages additive manufacturing techniques like laser powder bed fusion to enhance performance and reduce production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional fluid dispensing systems are used, then the system can deliver fuel, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The fuel ring is merged with the engine case through additive manufacturing, creating an integral structure where the fuel distribution channels are built directly within the engine case material. This eliminates separate fuel rail components and their associated joints and connections, reducing part count while maintaining fuel delivery function.
Solution Approach 2:
The manufacturing process transitions from conventional multi-part assembly to additive manufacturing, fundamentally changing the production parameter from mechanical assembly to layer-by-layer material deposition. This enables complex internal fuel channels to be created as integral parts of the engine case.
2Productivity
If conventional fuel rails with multiple parts are used, then the system can be assembled, but manufacturing time and costs increase
Solution Approach 1:
Multiple components (engine case, fuel ring, fuel manifold) are merged into a single additively manufactured unit. The fuel distribution channels are integrated directly into the engine case structure, eliminating the need for separate fuel rails and their assembly operations.
Solution Approach 2:
The fuel distribution channels are created during the initial additive manufacturing process of the engine case, rather than requiring subsequent assembly operations. The complex internal geometry is built in during the primary manufacturing step, eliminating later assembly time.
3Weight of moving object
If conventional fluid dispensing devices are used, then the system can function, but weight increases
Solution Approach 1:
The fuel distribution system is merged with the engine case structure, eliminating separate fuel rail components. The additive manufacturing process creates internal fuel channels within the case material itself, removing the weight of additional fuel delivery components.
Solution Approach 2:
The traditional fuel rail component is extracted from the system and its function is integrated directly into the engine case through additive manufacturing. This removes unnecessary material and components while maintaining the fuel distribution function.
Data Source
AI summary
An additively manufactured attritable engine includes an engine case, a fuel ring integral and conformal with the engine case, and a fuel manifold attached to the fuel ring and configured to deliver fuel to the fuel ring. The engine also includes a fuel injector attached to the fuel ring and configured to receive fuel from the fuel ring.