Radial Turbomachine Bladed Disc Assembly for Leakage Loss Reduction
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Solution Overview
Problem
Current methods for constructing bladed discs for radial turbomachines, such as die-casting, fail to achieve precise geometries and high efficiency, leading to increased production costs and reduced reliability, and lack effective reinforcement rings to minimize leakage losses.
Innovation Solution
A method involving the creation of bladed discs from solid materials, where blades and reinforcement rings are machined from a single piece or separate rings, allowing for precise definition and assembly to form annular sets, with techniques like milling and electrical discharge machining to ensure high precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If die-casting is used to produce bladed discs, then production speed is increased, but manufacturing precision and blade geometry accuracy deteriorate
Solution Approach 1:
The bladed disc is divided into separate components: the disc body and the blades. The disc is cast using die-casting for high productivity, while the blades are separately machined from solid material to achieve high precision geometries. This segmentation allows each component to be manufactured using the most appropriate process for its requirements.
Solution Approach 2:
The separately manufactured disc and blades are joined together through a combination process that integrates casting and machining operations. The disc body provides the base structure while the precision-machined blades are attached to achieve both high productivity and high manufacturing precision in the final assembled product.
2Device complexity
If reinforcement rings are not used in the rotor design, then device complexity is reduced, but energy loss due to leakage increases
Solution Approach 1:
Reinforcement rings are pre-positioned on the rotor disc at strategic locations before final assembly. These rings are designed to prevent leakage losses by sealing gaps between blades and the disc periphery, addressing the energy loss issue before the rotor begins operation.
Solution Approach 2:
The reinforcement rings act as intermediary elements between the blades and the disc structure. They serve as sealing surfaces that prevent fluid leakage while also providing structural support, thus reducing energy loss without significantly increasing overall device complexity.
3Ease of manufacture
If bosses are located between adjacent blades to mount rings, then ease of manufacture is improved, but harmful factors affecting fluid flow are increased
Solution Approach 1:
The harmful bosses that disturb fluid flow are extracted or removed from the design. Instead of placing mounting bosses between blades, the reinforcement rings are mounted using alternative methods such as interference fits, keyways, or distributed fastening points that do not protrude into the fluid passage and disrupt flow patterns.
Solution Approach 2:
The mounting features for reinforcement rings are designed with local quality considerations, placing fastening elements in locations that do not interfere with the main fluid flow path. The mounting structure is optimized to provide secure attachment while maintaining smooth flow surfaces in critical areas.
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 method reduces production costs, enhances the quality and structural precision of bladed discs, improving the reliability and efficiency of radial turbomachines by allowing precise blade formation and effective reinforcement, thereby minimizing leakage losses.
Implementation Method 1
techniques like milling and electrical discharge machining to ensure high precision and efficiency
Data Source
AI summary
The present invention concerns a method for the construction of bladed discs for radial turbomachines, comprising: preparing a disc (6, 14) provided with a front face (7); preparing a plurality of reinforcement rings (23) with different diameters. Preparing the disc (6, 14) comprises: realizing annular sets of blades (20) in one piece with the disc (6, 14), said sets (20) being concentric and coaxial with a central axis (X-X) and arranged on the front face (7), wherein each blade (20) has a leading edge (21) and a trailing edge (22) substantially parallel to the central axis (X-X); and/or preparing a plurality of reinforcement rings (23) comprises: realizing in one piece with each one of the reinforcement rings (23) an annular set of auxiliary blades (20′) arranged around a central axis (X-X), wherein each auxiliary blade (20′) has a leading edge (21′) and a trailing edge (22′) substantially parallel to the central axis (X-X). Each one of the reinforcement rings (23) is applied to the disc (6, 14) at one of the annular sets of blades (20) and/or auxiliary blades (20′), so as to define on the front face (7) annular sets of blades (20) and/or auxiliary blades (20′), each one provided with a respective reinforcement ring (23).