Integrally Bladed Rotor Repair for Mistuning Vibration Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Integrally bladed rotors in gas turbine engines experience unique vibrational characteristics due to manufacturing tolerances and wear, leading to mistuning, which results in uneven blade vibration and increased susceptibility to high cycle fatigue damage, making it challenging to determine optimal repair shapes that address these issues effectively.
Innovation Solution
A method and system for repairing integrally bladed rotors that involve performing vibratory analysis on a rotor module, determining undesirable vibratory characteristics, and iterating potential repair shapes to eliminate these issues, using computational fluid dynamics models and boundary conditions based on test engine data to select a repair shape that reduces vibratory stress below a threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional IBR manufacturing methods are used, then production is achieved, but manufacturing precision deteriorates due to tolerances causing blade variation and mistuning
Solution Approach 1:
The patent performs vibratory analysis and determines undesirable vibratory characteristics before finalizing the repair shape. By anticipating and addressing mistuning issues in advance through computational modeling and iteration, the system prevents further degradation of blade uniformity while maintaining manufacturing feasibility.
Solution Approach 2:
The system iterates through multiple potential repair shapes with varying geometries to optimize vibratory characteristics. By changing geometric parameters of the repair shape and evaluating their impact on mistuning, the system achieves improved blade uniformity without requiring complete remanufacturing.
2Reliability
If repair shapes are selected without considering mistuning, then repair process is simplified, but reliability deteriorates due to increased susceptibility to high cycle fatigue damage
Solution Approach 1:
The system performs comprehensive vibratory analysis and determines undesirable vibratory characteristics before selecting the final repair shape. This preliminary assessment ensures that the chosen repair shape will not exacerbate mistuning and will improve fatigue resistance, making the complex analysis worthwhile for enhanced reliability.
Solution Approach 2:
The patent uses computational modeling and simulation to rapidly evaluate multiple repair shape options without requiring physical prototyping or extensive testing. This allows the system to efficiently navigate the complex design space and identify optimal repair shapes that improve reliability while managing analysis complexity.
3Duration of action of stationary object
If individual blade variations are not addressed, then manufacturing is easier, but durability deteriorates due to uneven vibration and high cycle fatigue damage
Solution Approach 1:
The system applies localized repair shapes to specific blades based on their individual vibratory characteristics and mistuning contributions. Rather than requiring uniform repairs across all blades, the system tailors repairs to address local variations, thereby extending rotor lifespan while managing repair complexity through targeted interventions.
Data Source
AI summary
A method of repairing an integrally bladed rotor (IBR) may comprise: performing a vibratory analysis of a rotor module including a first inspected IBR with a potential repair shape for the IBR; determining an undesirable vibratory characteristic of a second inspected IBR in the rotor module; iterating the potential repair shape for the first IBR to eliminate the undesirable vibratory characteristic of the second inspected IBR; and repairing the first IBR with a selected repair shape based on determining the potential repair shape eliminates the undesirable vibratory characteristic.