Bearing Compartment Support Structure With Separable Spring Section
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Solution Overview
Problem
Existing additive manufacturing processes for gas turbine engine bearing compartments fail to consider assembly aspects and component use, leading to inefficient support structure design for complex geometries.
Innovation Solution
A support structure with a spring portion and upper portion, integrally formed within the bearing compartment, which can be separated post-manufacturing to function as a spring, featuring a lattice structure and struts for enhanced stability and tunable stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If support structures are designed using modeling tools based on component geometry only, then the support structures can be generated automatically, but the design does not consider assembly aspects and component use leading to inefficiency
Solution Approach 1:
The support structure is segmented into a first portion and a second portion that can be separated from each other. The first portion remains in the bearing compartment while the second portion is removed to form a spring. This segmentation allows the support structure to serve multiple functions during manufacturing and operation, resolving the contradiction between automated design and assembly efficiency.
Solution Approach 2:
The support structure is designed to perform multiple functions: it provides structural support during additive manufacturing, serves as a temporary support feature, and transforms into a functional spring component after separation. This multi-functionality eliminates the need for separate assembly steps and improves overall manufacturing efficiency.
2Ease of manufacture
If the support structure is designed with minimum support for later removal, then the manufacturing process is simplified, but the structural stability during additive manufacturing is compromised
Solution Approach 1:
The support structure transitions from a static support feature during manufacturing to a dynamic spring component after separation. The spring portion is designed with configurable stiffness through lattice structures that can be tuned to provide adequate support during manufacturing while enabling easy separation and functional operation as a spring.
Solution Approach 2:
The stiffness and structural properties of the spring portion are made configurable through lattice structure parameters. By adjusting the lattice geometry and material distribution, the support structure can provide maximum stability during additive manufacturing while maintaining the ability to be easily separated and function as a spring with tuned performance characteristics.
3Adaptability or versatility
If the spring portion is created with configurable stiffness through lattice structures, then the spring performance can be tuned, but the device complexity increases
Solution Approach 1:
Different regions of the spring portion have different lattice structures with varying stiffness characteristics. By applying local quality variations in the lattice geometry, the spring can be tuned to provide specific performance characteristics at different locations while maintaining overall structural integrity and managing complexity through targeted design variations.
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
Enables the creation of complex geometries with improved structural stability and tunable spring performance, facilitating efficient assembly and operation of gas turbine engines.
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
AI summary
A bearing compartment includes a housing having an upper housing portion and a lower housing portion, and a support structure fabricated within the bearing compartment. The support structure includes an upper portion within the upper housing portion and a spring section within the lower housing portion. The spring section includes a plurality of struts and is separable from the support structure for use as a spring within the housing.