Composite Gas Turbine Casing with Local Thickness Variation
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Solution Overview
Problem
Existing gas turbine casings made of composite materials face challenges in varying thickness non-axisymmetrically without degrading the mechanical properties through machining, which is undesirable as it cuts yarns and affects performance.
Innovation Solution
A method involving three-dimensional weaving of fibrous textures with varying weft yarn counts or sizes to create sections of different thicknesses, allowing for localized thickness variations in the casing without machining, enabling the formation of thickened sections for reinforcement and thinned sections for clearance, thus optimizing the casing's geometry and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If machining is used to form local thickness variations in the casing, then the casing can have localized thickness variations, but the mechanical properties of the composite material are degraded due to yarn cutting
Solution Approach 1:
The invention applies preliminary action by incorporating variable thickness directly into the fibrous texture during the weaving process, before the casing is manufactured. Different weft yarn counts are integrated into specific zones of the fibrous texture, so that when the casing is formed, the desired local thickness variations are already present without requiring subsequent machining operations that would cut yarns and degrade mechanical properties
Solution Approach 2:
The invention applies local quality by varying the weft yarn count in specific zones of the fibrous texture to create local thickness variations. Different zones of the casing have different weft yarn densities, resulting in localized thick or thin sections that are tailored to specific functional requirements, while maintaining the integrity of the composite material structure throughout
2Weight of moving object
If the casing thickness is reduced in non-critical areas, then the overall mass of the casing is lightened, but the structural integrity may be compromised
Solution Approach 1:
The invention applies local quality by creating zones with different weft yarn counts in the fibrous texture, resulting in localized thickness variations in the casing. Critical areas maintain higher weft yarn counts for structural integrity, while non-critical areas have reduced weft yarn counts to minimize mass, achieving an optimized balance between weight reduction and structural strength
Solution Approach 2:
The invention applies parameter changes by varying the weft yarn count parameter across different zones of the fibrous texture. This allows continuous adjustment of local thickness and mass distribution while maintaining overall structural integrity, optimizing the casing for both weight reduction and strength requirements
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 approach allows for the creation of gas turbine casings with localized thickness variations, enhancing mechanical reinforcement and reducing space requirements, thereby improving the casing's structural integrity and assembly compatibility without degrading the composite material's mechanical properties.
Implementation Method 1
the densification of the preform by a matrix being able to be in particular obtained by injection and polymerization of a resin in the fibrous preform
Data Source
AI summary
A gas turbine fan casing made of composite material with a fibrous reinforcement includes a plurality of superimposed turns of a strip-shaped fibrous texture having a three-dimensional weaving between a plurality of layers of warp yarns and a plurality of layers of weft yarns, the fibrous reinforcement being densified by a matrix. The fibrous texture includes at least one lateral section of variable thickness in which the weft yarns have a size or a count different from the size or the count of the weft yarns of the plurality of layers of weft yarns present in the remainder of the fibrous texture.