Gas Turbine Bearing Housing Segmentation for Additive Manufacture
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Solution Overview
Problem
Existing methods for manufacturing gas turbine engine bearing housings face challenges in meeting stringent performance, safety, and reliability requirements due to harsh temperature environments and stress/vibrational modes, with traditional manufacturing processes being time-consuming and costly.
Innovation Solution
The method involves producing segments of the bearing housing using additive manufacturing, particularly the intermediate structure segment, which includes a branch member and fluid conduit, and attaching these segments via weldments to form a complex bearing housing that meets performance and reliability criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for bearing housings, then manufacturing precision and structural integrity can be achieved, but manufacturing time and costs increase significantly
Solution Approach 1:
The bearing housing is divided into multiple segments that are manufactured separately using additive manufacturing and then assembled together. This segmentation allows parallel production of multiple components, significantly reducing total manufacturing time while maintaining the integrity of each individual segment through precise additive manufacturing processes.
Solution Approach 2:
Complex internal features such as fluid conduits and branch members are incorporated directly into the additive manufacturing process during the preliminary manufacturing stage, eliminating the need for subsequent complex machining operations. This preliminary action ensures structural integrity is achieved during manufacturing rather than requiring extensive post-processing.
2Ease of manufacture
If traditional manufacturing processes are used for bearing housings, then conventional structural designs can be produced, but manufacturing costs and production time increase
Solution Approach 1:
The patent transitions from conventional subtractive or formative manufacturing to additive manufacturing, adding a new dimensional approach to production. This enables complex three-dimensional structures with internal fluid conduits and branch members to be built directly layer-by-layer, dramatically improving manufacturing efficiency and enabling designs that were previously impossible or prohibitively expensive to manufacture.
Solution Approach 2:
Multiple bearing housing segments are manufactured with integrated fluid conduits and connection features that align and connect during assembly. This merging of multiple functional elements into integrated segments reduces the number of separate manufacturing operations and assembly steps, thereby improving overall productivity while maintaining ease of manufacture through standardized connection interfaces.
3Adaptability or versatility
If complex bearing housing structures with fluid conduits are manufactured using traditional methods, then functional requirements can be met, but manufacturing complexity and costs increase
Solution Approach 1:
The bearing housing is segmented into multiple modules, each containing integrated fluid conduits and branch members designed for specific functions. This segmentation allows each module to be optimized independently for its fluid handling requirements, enhancing adaptability and versatility while reducing overall manufacturing complexity through modular assembly of standardized components.
Solution Approach 2:
The additive manufacturing process creates universal segment designs with standardized fluid conduit interfaces and connection features that can be adapted to different engine configurations and bearing housing applications. This universality allows the same basic segment design to serve multiple functions and be configured for different operational requirements, reducing manufacturing process complexity through design standardization.
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 reduces manufacturing time and costs while enhancing the mechanical properties and integration of fluid conduits, enabling the production of bearing housings that meet stringent requirements and facilitate adaptable designs for different engine configurations.
Implementation Method 1
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
Implementation Method 2
the flange outer structure segment may be attached to the outer radial end of the intermediate structure segment by weldment
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of manufacturing an annular bearing housing (54) for a gas turbine engine includes: producing a flange outer structure segment (58); producing an intermediate structure segment (60) having an outer radial end (76), an inner radial end (78), a body (74) that extends between the outer radial end (76) and the inner radial end (78), and a branch member (84) that extends outwardly from the body (74); producing a main body segment (62); attaching the flange outer structure segment (58) to the outer radial end (76) of the intermediate structure segment (60); and attaching the main body segment (62) to the inner radial end (78) of the intermediate structure segment (60). At least one of the flange outer structure segment (54), the intermediate structure segment (60), or the main body segment (62) is produced using an additive manufacturing process.