Mist Lubrication Channel for Attritable Engine Ball Bearings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid dispensing systems in attritable aircraft engines are complex and costly, with cross-drilling adding labor and expense, and improper lubrication can lead to catastrophic failures due to insufficient or excessive lubrication fluid, affecting engine efficiency and weight.
Innovation Solution
A lubrication system with a dispersion cone that forms a mist of lubricant to evenly cover ball bearing assemblies, integrated using additive manufacturing techniques, eliminating the need for cross-drilling and optimizing lubricant distribution, reducing production costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid dispensing systems with multiple parts and cross-drilling are used, then proper lubrication can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The dispersion cone is integrated directly into the lubrication channel outlet, eliminating the need for separate dispensing components. This merging of functions reduces the number of parts from five or more to a single integrated structure, simplifying manufacturing while maintaining proper lubrication delivery to ball bearing assemblies
Solution Approach 2:
The lubrication channel is divided into distinct functional zones: an inlet portion, a dispersion cone portion with atomizing features, and an outlet portion. This segmentation allows each zone to perform its specific function optimally while being manufactured as a single integrated component through additive manufacturing
2Temperature
If excessive lubrication fluid is provided, then sufficient cooling of bearings is ensured, but system footprint and weight increase
Solution Approach 1:
The dispersion cone transforms the lubrication fluid from a continuous stream into a fine mist or spray pattern through atomizing features. This parameter change in fluid delivery method increases the surface area of lubricant contact with bearing surfaces, improving cooling efficiency while reducing the total volume of lubricant required in the system
Solution Approach 2:
The atomizing features create localized high-concentration lubricant mist precisely where needed at the bearing contact points. This localized delivery ensures sufficient cooling where required while avoiding excessive lubricant throughout the entire system, reducing overall weight and footprint
3Ease of manufacture
If cross-drilling is used to create fluid passageways, then necessary fluid flow paths are established, but labor and manufacturing time increase
Solution Approach 1:
Additive manufacturing replaces conventional subtractive manufacturing methods like cross-drilling. The lubrication channels and dispersion cone are built layer-by-layer in a single additive process, eliminating the need for multiple drilling operations, alignment steps, and assembly operations required by traditional mechanical fabrication methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The lubrication system efficiently cools ball bearing assemblies, simplifies manufacturing, and reduces overall production costs and engine weight by providing the right amount of lubrication, enhancing engine performance and efficiency.
Implementation Method 1
a dispersion cone configured to form a mist of the lubricant
Implementation Method 2
The evenly distributed lubricant cools ball bearing assemblies during operation of the engine
Data Source
AI summary
A gas turbine engine with a lubrication system includes a ball bearing assembly and a rotor circumscribing a rotational axis and journaled within the ball bearing assembly. The gas turbine engine also includes a lubrication system located radially outward from a rotational axis and radially outward and adjacent to the ball bearing assembly, which includes a lubrication channel having an inlet and an outlet and a dispersion cone adjacent to the outlet of the lubrication channel.