Composite Bladed Disk Segmentation for Economical Blade Integration

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Solution Overview

Problem

Conventional manufacturing techniques for composite bladed disks or rotors in gas turbine engines are complex and uneconomical, requiring intricate tooling and assembly processes, especially when mounting blades on composite materials.

Innovation Solution

A method involving forming a moulded component from composite materials, segmenting it into adjacent segments with complementary finger joint profiles and slots, and positioning blades within these slots to create a reliable structural joint, allowing for flexible material choice and economical production without complex tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional manufacturing techniques are used for composite bladed disks, then the disk can be manufactured from composite materials, but the manufacturing process becomes complex and uneconomical

Engineering Contradiction:

Improveweight of bladed diskVSAvoidmanufacturing process complexity

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The composite bladed disk is divided into multiple segments that are manufactured separately and then joined together. Each segment can be manufactured using simpler, more economical processes, and the segments are connected through finger joint profiles that interlock to form the complete structure. This segmentation allows for easier manufacturing while maintaining the weight benefits of composite materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing process merges multiple discrete segments into a single integrated bladed disk structure through the finger joint connection system. The segments are combined with blades integrated into the composite structure, creating a unified component that achieves both weight reduction and structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If conventional assembly processes are used for mounting blades on composite disk, then blades can be mounted on the disk, but the assembly process becomes complicated

Engineering Contradiction:

Improveblade mounting processVSAvoidassembly process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The blades are pre-integrated into the composite disk structure during the manufacturing process rather than being attached separately during assembly. The finger joint profiles are formed as part of the composite molding process, creating ready-to-connect features that simplify the final assembly operation. This preliminary action eliminates complex separate mounting steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The blades are nested within slots formed in the composite disk structure, with the finger joint profiles providing interlocking features. The hierarchical integration of blades within the disk segments creates a compact, integrated assembly that reduces complexity compared to external mounting approaches.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If the molded component is segmented into multiple segments, then manufacturing becomes simpler, but the structural joint between segments must be reliable

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural joint reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The finger joint profiles are manufactured using composite materials that provide both the necessary strength and stiffness for reliable structural connections. The composite material properties are tailored to ensure the joints can withstand operational loads while maintaining the overall weight benefits of the composite bladed disk.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The finger joint profiles incorporate curved and interlocking geometries that enhance the mechanical interconnection between segments. The curved finger profiles distribute stresses more effectively and create more reliable mechanical bonds compared to simple flat joints, ensuring structural integrity while maintaining manufacturing simplicity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS12359571B2Method for manufacturing a composite bladed disk or rotor

Publication Date: 2025.07.15 ROLLS ROYCE PLC

AI summary

A method includes forming a moulded component that is axisymmetric about a component axis; segmenting the moulded component into a plurality of segments, each pair of adjacent segments including a pair of surfaces that is formed during segmentation of the moulded component; providing, via computerised numerical control machining, complementary finger joint profiles on the pair of surfaces of the each pair of adjacent segments; providing a plurality of slots on at least one of the pair of surfaces of the each pair of adjacent segments; positioning a plurality of blades partially within the plurality of slots; mating the complementary finger joint profiles provided on the pair of surfaces of the each pair of adjacent segments; and joining the each pair of adjacent segments to each other, such that the plurality of blades is retained within the plurality of slots.