Composite Guide Vane Axially Offset Flanges
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Solution Overview
Problem
Existing methods for fabricating guide vanes for gas turbine engines using composite materials face challenges such as weaving constraints, difficulty in managing thickness variations, and the need for fillers to reduce stress, particularly when forming non-interlinked fastener flanges.
Innovation Solution
A composite material guide vane with axially offset fastener flanges formed through three-dimensional weaving, eliminating the need for non-interlinking in the fiber preform, reducing the number of layers required, and eliminating the need for fillers, thereby simplifying the fabrication process and reducing weight and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If non-interlinked portions are used to form fastener flanges in the fiber preform, then the fastener flanges can be formed on opposite side faces of the airfoil, but the number of layers of strands must be increased and the fabrication complexity increases
Solution Approach 1:
The patent introduces axial offset between fastener flanges positioned on opposite side faces of the airfoil. This dimensional arrangement allows flanges to be formed on both pressure and suction sides without requiring non-interlinked portions, as the axial offset provides sufficient space for each flange to be formed from interlinked portions of the preform.
Solution Approach 2:
The patent merges the formation of multiple fastener flanges into a single interlinked preform structure. By using axially offset positioning, all flanges can be created from one continuous woven preform without requiring separate non-interlinked sections, thereby reducing fabrication complexity while maintaining the ability to attach to multiple surfaces.
2Adaptability or versatility
If non-interlinked portions are used to form fastener flanges, then the flanges can be created on opposite side faces, but the number of layers of strands must be increased
Solution Approach 1:
The axial offset arrangement positions fastener flanges at different axial locations on opposite side faces of the airfoil. This dimensional separation allows the use of fewer layers of strands, as each flange can be formed from interlinked portions without requiring the additional layers that would be needed for non-interlinked configurations.
3Adaptability or versatility
If non-interlinked portions are used to form fastener flanges, then the flanges can be formed on opposite side faces, but fillers must be woven to fill voids and reduce stresses
Solution Approach 1:
By positioning fastener flanges at axially offset locations on opposite side faces, the patent eliminates the creation of voids that would require filler materials. The axial separation ensures that interlinked portions can form both flanges without creating gaps, thereby eliminating the need for additional filler weaving steps and associated stress management.
4Quantity of substance
If axially offset fastener flanges are used, then the number of layers of strands is reduced, but the fastener flanges must be positioned at different axial locations
Solution Approach 1:
The patent accepts the axial positioning constraint as a beneficial feature rather than a limitation. By deliberately designing the fastener flanges to be axially offset, the invention reduces the number of layers of strands needed while creating a structured three-dimensional arrangement that simplifies the preform configuration and eliminates the need for non-interlinked portions.
Data Source
AI summary
A composite material guide vane for a gas turbine engine, the composite material including fiber reinforcement densified by a matrix, the fiber reinforcement being formed as a single piece by three-dimensional weaving and including an airfoil and at least two fastener flanges extending from a radial end of the vane towards opposite side faces of the airfoil, the fastener flanges being axially offset from each other.