Chamfered Stator Vane Rail Airflow Recirculation
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Solution Overview
Problem
Gas turbine engines face inefficiencies and durability issues due to losses in cooling air delivery, which affect fuel burn, performance, and component durability, particularly in the stator vane assemblies and rotor assemblies.
Innovation Solution
The implementation of a chamfered stator vane rail with angled, curved, or sinusoidal surfaces on the ID and OD stator vane rails to improve airflow by reducing recirculation and enhancing the efficiency of cooling air delivery, including features like chamfered edges and feather seal slots to minimize airflow leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stator vane rails are used, then the structure is simple, but cooling air delivery efficiency is poor with significant recirculation losses
Solution Approach 1:
The stator vane rail incorporates curved surfaces including a bow-tied surface and sinusoidal surface that extend radially outward. These curved geometries are designed to optimize airflow patterns, reduce recirculation zones, and improve cooling air delivery efficiency to the rotor assembly while maintaining structural integrity.
Solution Approach 2:
The invention modifies the geometric parameters of the stator vane rail by introducing chamfered faces at specific angles (15°-45° or 45°-60° relative to the axial direction) and varying radial distances. These parameter changes are optimized to control airflow direction and reduce recirculation losses, thereby improving cooling air delivery efficiency.
2Reliability
If cooling air delivery is improved, then component durability increases, but airflow losses and recirculation must be reduced
Solution Approach 1:
The stator vane rail features locally optimized surfaces including chamfered faces at the leading and trailing edges, curved radial surfaces, and bow-tied/sinusoidal profiles at specific locations. These localized geometric features are designed to control airflow behavior in critical regions, reducing recirculation losses and improving cooling air delivery to where it is most needed, thereby enhancing component durability while minimizing energy losses.
3Productivity
If chamfered surfaces are added to reduce recirculation, then cooling airflow efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The curved surfaces including bow-tied and sinusoidal profiles are designed to be integrally formed with the stator vane rail structure. While these complex geometries improve cooling airflow efficiency by reducing recirculation, they are manufactured as single-piece components using advanced manufacturing techniques, thereby limiting the increase in manufacturing complexity.
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 design results in improved airflow pressure and temperature, reducing thermal stress and enhancing the durability of engine components by increasing cooling airflow efficiency by 5-10% and minimizing recirculation, thereby improving overall engine performance.
Implementation Method 1
the chamfered face of the stator vane rail may be oriented at an angle of about 45° to about 60° relative to the axis
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A chamfered stator vane rail (220) is provided. The chamfered stator vane rail (220) comprises a forward rail (225) and an aft rail (230; 330) axially opposite the forward rail. The aft rail (230; 330) comprises a leading edge (232) and a trailing edge (237) located axially opposite and aft of the leading edge. The aft rail (230) comprises a chamfered edge (234; 334-1; 334-2; 334-3) on a radially outer surface. The chamfered edge (234; 334-1; 334-2; 334-3) may be oriented at an angle relative to an axis (290).