Bonded Mount Ring Spinner for Gas Turbine Fan Assembly
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Solution Overview
Problem
Current gas turbine engine spinners with integral support flanges cannot be fabricated using injection molding due to the lock-on condition caused by the aft support flange, preventing the creation of a separate bonded support component.
Innovation Solution
A fan assembly with a support ring that is bonded to the spinner, featuring a first portion facing the fan hub and a second portion connected to the spinner at a joint, allowing for separate fabrication and assembly, including the use of bonding rails and adhesives like epoxy or silicone, enabling the transfer of axial, radial, and shear forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support flange is integrated into the spinner as a single component, then the structural strength and durability are improved, but the manufacturing complexity increases and injection molding cannot be used due to the lock-on condition
Solution Approach 1:
The support flange is separated from the spinner body, creating two distinct components: the spinner and the support flange. This segmentation allows the spinner to be manufactured using injection molding while the support flange can be produced separately and then attached, resolving the lock-on condition that prevented integral molding.
Solution Approach 2:
The support flange is bonded to the spinner body through a bonding joint, merging the two separate components into a unified structural assembly. This bonding process restores the structural integrity equivalent to an integral construction while enabling separate manufacturing processes.
2Ease of manufacture
If the support flange is separated into a different component, then the manufacturing flexibility and cost are improved, but the connection strength and durability may be compromised
Solution Approach 1:
A bonding agent serves as an intermediary material between the support flange and the spinner body. This bonding agent creates a strong, durable connection that transfers loads effectively, mediating between the separated components to restore the structural integrity of an integral design.
Solution Approach 2:
The bonding joint utilizes composite material principles by combining the support flange, spinner body, and bonding agent into a multi-material assembly. This composite structure leverages the advantages of each material to achieve both manufacturing flexibility and connection strength.
3Ease of manufacture
If injection molding is used to fabricate the spinner, then the production cost is reduced, but the traditional integral support flange design cannot be implemented
Solution Approach 1:
The design is segmented into the spinner and support flange as separate components, allowing the spinner to be manufactured via injection molding at reduced cost, while the support flange is produced separately and bonded to the spinner, maintaining the necessary structural functionality.
Solution Approach 2:
The support flange is extracted from the integral spinner structure, allowing the spinner to be manufactured independently using cost-effective injection molding processes, while the support flange is produced as a separate component and assembled later.
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 use of injection molding for spinner components while maintaining durability and adhering to FAA regulations, reducing production costs and wear on the engine by allowing separate fabrication and assembly of support components.
Implementation Method 1
the connection between the second portion and the joint is a bonded connection
Data Source
AI summary
A fan assembly of a gas turbine engine, a method for fabricating a fan assembly for a gas turbine engine, and a gas turbine engine are disclosed. The fan assembly of the gas turbine engine may include a spinner section, a fan hub section aft of the spinner section, and a joint therebetween. The fan assembly may further include a support ring for internally supporting the spinner, the support ring including a first portion facing the fan hub and a second portion connected to the spinner at the joint, wherein the connection between the second portion and the joint is a bonded connection.