Inspected Bladed Rotor Repair Blend Evaluation with Dual Simulation
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Solution Overview
Problem
Current repair methods for integrally bladed rotors (IBRs) in gas turbine engines are limited, as they fail to consider functional assessments such as aerodynamic stability and structural durability, leading to unnecessary scrapping of damaged rotors without exploring more optimal repair options.
Innovation Solution
A method involving the generation of a digital representation of a repaired bladed rotor based on inspection data, followed by structural and aerodynamic simulations to determine if the repair meets experience-based criteria, including modal assurance criteria, resonant frequency, and aerodynamic efficiency, allowing for the determination of suitable repair blend profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional geometric assessment constraints (tolerances, material removal, material addition) are used for IBR repair evaluation, then the repair process is simple and quick, but many potentially repairable IBRs are incorrectly classified as unrepairable, leading to unnecessary scrapping
Solution Approach 1:
The patent transitions from purely geometric parameters (tolerances, material volumes) to functional parameters (aerodynamic stability, structural durability) by implementing computational simulations. This parameter transformation allows the system to evaluate IBR repairability based on actual functional performance rather than rigid geometric constraints, enabling previously discarded components to be identified as repairable.
Solution Approach 2:
The patent replaces manual expert assessment and simple geometric measurement systems with automated computational mechanics systems. Finite element analysis and computational fluid dynamics simulations automatically evaluate structural and aerodynamic performance, substituting human judgment with objective, repeatable computational assessments that can process multiple parameters simultaneously.
2Reliability
If functional assessments (aerodynamic stability, structural durability) are incorporated into IBR repair evaluation, then repair suitability accuracy is improved, but the assessment process becomes more complex and time-consuming
Solution Approach 1:
The patent divides the complex functional assessment into separate modular simulation components: structural analysis modules for structural durability, aerodynamic analysis modules for aerodynamic stability, and blending analysis modules for repair geometry evaluation. Each module independently assesses specific functional aspects, allowing the complex overall assessment to be managed through coordinated simpler sub-assessments.
Solution Approach 2:
The patent creates digital replicas (virtual models) of the IBR and repair scenarios, allowing functional assessments to be performed on these copies rather than requiring physical testing of actual components. This digital copying enables repeated, cost-free simulations that evaluate different repair approaches without affecting the physical integrity of the original component.
3Reliability
If multiple simulation types (structural, aerodynamic, blending) are performed to evaluate IBR repairs, then comprehensive functional assessment is achieved, but computational resources and time requirements increase
Solution Approach 1:
The patent performs preliminary blending analysis to evaluate repair geometry before conducting more computationally intensive structural and aerodynamic simulations. By assessing the feasibility of repair blend profiles first, the system can eliminate unrealistic repair approaches early, avoiding wasted computational resources on simulations that would inevitably fail.
Solution Approach 2:
The patent implements a tiered assessment approach where not all simulation types are performed for every IBR case. Simpler geometric and blending assessments are performed first, and only cases that pass these preliminary checks proceed to full structural and aerodynamic simulations. This partial action approach reduces overall computational burden while maintaining assessment completeness for viable candidates.
Data Source
AI summary
A method can comprise: generating, via a processor, a digital representation of a portion of a repaired bladed rotor, the digital representation based on a geometrical dimensions determined from an inspection of an inspected bladed rotor and a repair blend profile for a defect of the inspected bladed rotor; performing, via the processor, a structural simulation on a structural model, the structural model based on the digital representation of the repaired bladed rotor; performing, via the processor, an aerodynamic simulation on an aerodynamic model, the aerodynamic model based on the digital representation of the repaired bladed rotor; and determining, via the processor, whether results from the structural simulation and the aerodynamic simulation meet an experience based criteria for the repaired bladed rotor.