Additive Manufacturing Bearing Support with Alternating Cross-Sections
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Solution Overview
Problem
Conventional methods for manufacturing aircraft engine bearing supports are complex and expensive, involving multiple processes and requiring extensive cellular supports during additive manufacturing, which complicates post-manufacturing reworking and assembly.
Innovation Solution
A bearing support manufactured in a single piece using powder-bed additive manufacturing with a cylindrical element and annular stiffener featuring alternating Γ-shaped and Y-shaped cross-sections, reducing the need for cellular supports and simplifying post-additive manufacturing reworking by incorporating ramps and recesses for efficient machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to manufacture bearing supports, then manufacturing precision and structural integrity can be achieved, but the manufacturing process becomes complex and expensive involving multiple processes and extensive cellular supports
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. The bearing support, cellular supports, and mounting features are all manufactured as one integrated component in a single build operation, eliminating the need for separate manufacturing steps and reducing overall process complexity despite the intricate geometry required
2Reliability
If extensive cellular supports are used during additive manufacturing, then structural integrity during manufacturing is maintained, but post-manufacturing reworking becomes complicated and requires specialized tools
Solution Approach 1:
The patent applies local quality by providing cellular supports only in specific regions where they are structurally necessary during manufacturing, rather than uniformly throughout the entire component. The alternating Γ-shaped and Y-shaped cross-sections create localized support structures that maintain integrity during printing but are strategically positioned to minimize interference with post-manufacturing operations
3Ease of manufacture
If the stiffener has uniform cross-section, then manufacturing is simpler, but structural performance and support during additive manufacturing are insufficient
Solution Approach 1:
The stiffener employs varying cross-sectional geometries (alternating between Γ-shaped and Y-shaped) along its circumference to provide locally optimized structural performance. This non-uniform design delivers enhanced strength and support during additive manufacturing in critical regions while maintaining manufacturability through the systematic alternation of cross-section types
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 minimizes the quantity of cellular supports required during manufacturing, simplifies machining, and reduces the need for specialized tools, thereby lowering costs and improving the efficiency of the bearing support's assembly and integration into aircraft engines.
Implementation Method 1
manufactured in one piece by powder-bed additive manufacturing from a manufacturing platform
Data Source
AI summary
A bearing support for an aircraft engine, manufactured, in one piece, by powder-bed additive manufacturing from a manufacturing platform, including a cylindrical element including an annular stiffener with a cross-section that changes along its circumference, this stiffener being formed with alternating portions having a Γ-shaped cross-section, needing to be supported during the manufacture, and portions having a Y-shaped cross-section that are not supported during the manufacture.