Bearing Compartment Support Structure With Tunable Spring Struts
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Solution Overview
Problem
Gas turbine engines with complex geometries, such as bearing compartments, face challenges in additive manufacturing due to the need for support structures that do not consider assembly aspects, leading to inefficient use of materials and potential structural instability.
Innovation Solution
A support structure within the bearing compartment is fabricated with a spring section and upper portion, featuring a plurality of struts and an internal lattice structure, which can be separable and integrally formed with the compartment, allowing for machining to tune spring performance and remove the support structure post-manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are designed by modeling tools based on component geometry, then the support structures can support overhangs and complex geometry, but the design does not consider assembly aspects leading to inefficient material use and potential structural instability
Solution Approach 1:
The support structure is divided into two distinct segments: a permanent support structure that remains in the bearing compartment, and a temporary support structure that is removed after manufacturing. This segmentation allows each part to be optimized for its specific function - the permanent structure uses minimal material for long-term support, while the temporary structure provides build-time support without compromising final material efficiency
Solution Approach 2:
The temporary support structure is designed to be extracted or removed after the additive manufacturing process completes. This extraction principle allows the temporary structure to fulfill its support function during manufacturing, then be discarded to achieve material efficiency in the final product, directly resolving the contradiction between manufacturing ease and material waste
2Loss of substance
If support structures are designed with minimum support for later removal, then material use is reduced, but structural stability during manufacturing may be compromised
Solution Approach 1:
By segmenting the support system into temporary and permanent components, the design achieves structural stability during manufacturing through the temporary structure, then transitions to material efficiency after removal. The permanent structure is designed from the outset to provide adequate stability without excessive material, as it doesn't need to support overhangs during the build process
Solution Approach 2:
The temporary support structure acts as an intermediary element that provides structural stability only during the manufacturing process. It mediates between the conflicting requirements of stability and material efficiency by being present when stability is needed and absent when material efficiency is prioritized
3Adaptability or versatility
If the spring section is separable from the support structure, then the spring can be used as a functional component, but the manufacturing process becomes more complex
Solution Approach 1:
The support structure is segmented into separable components including a permanent support structure and a temporary support structure that contains the spring section. This segmentation enables the spring to be extracted and reused as a functional component, while the permanent support structure remains in place. The segmentation is designed to simplify overall manufacturing by allowing modular production and assembly
Solution Approach 2:
The spring section is designed to serve multiple functions: it acts as a temporary support element during additive manufacturing, provides structural support in the final assembled product, and can be extracted for reuse as a functional spring component. This multi-functionality justifies the separable design and reduces overall device complexity by eliminating the need for separate springs
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
This approach enables the creation of complex geometries with enhanced structural stability and efficient use of materials, allowing the spring portion to be used as a functional component within the gas turbine engine, improving both structural integrity and manufacturing efficiency.
Implementation Method 1
The spring section includes a plurality of struts and is separable from the support structure for use as a spring within the housing
Data Source
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AI summary
According to an aspect, a bearing compartment (202) includes a housing (230) having an upper housing portion (234) and a lower housing portion (232), and a support structure (220) fabricated within the bearing compartment (202). The support structure (220) includes an upper portion (224) within the upper housing portion (234) and a spring section (222) within the lower housing portion (232). The spring section (222) includes a plurality of struts (282) and is separable from the support structure (220) for use as a spring within the housing (230).