Composite Splitter Lip Anchoring for Axial Compressor
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Solution Overview
Problem
Existing splitter lips for axial turbomachines face challenges in providing robustness and weight reduction while minimizing stress concentrations and simplifying assembly, as traditional attachment methods like screws lead to weak connections and potential stress concentrations.
Innovation Solution
A splitter lip design featuring a composite downstream partition and a metallic upstream partition with an integrated anchoring portion, utilizing a network of interconnected junctions and materials with intermeshed anchoring roughnesses and openings to enhance anchoring and reduce weight, allowing for a bi-material configuration that optimizes strength and weight savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to attach the axial flange to the acoustic panel, then the splitter lip can be assembled, but stress concentrations occur and the connection becomes weak
Solution Approach 1:
The patent replaces the mechanical screw attachment system with a bonded joint system using adhesive. The axial flange is provided with a bonding surface that directly bonds to the acoustic panel, eliminating screws and their associated stress concentrations while providing a more reliable, distributed connection across the entire bonding interface.
Solution Approach 2:
The patent changes the attachment mechanism from discrete mechanical fasteners to a continuous bonded joint. This parameter change transforms the stress distribution from concentrated points at screw locations to a distributed pattern across the entire bonding surface, improving connection reliability while reducing peak stress concentrations.
2Reliability
If traditional metal splitter lip design is used, then robustness is achieved, but weight increases leading to higher fuel consumption
Solution Approach 1:
The patent employs composite materials by bonding the axial flange (made of metal for robustness) to the acoustic panel (made of lighter material). This composite construction allows the splitter lip to achieve the required robustness and strength while reducing overall weight compared to a fully metal design, thereby lowering fuel consumption.
Solution Approach 2:
The splitter lip is divided into separate components (axial flange and acoustic panel) that can be made from different materials optimized for their specific functions. The axial flange provides structural robustness where needed, while the acoustic panel provides acoustic functionality with reduced weight, and the bonding surface joins these segments together.
3Ease of manufacture
If a simple attachment method is used, then assembly is simplified, but the connection strength is insufficient
Solution Approach 1:
The patent replaces complex mechanical attachment systems (screws, fasteners, multiple steps) with a simpler bonded joint system. The bonding surface on the axial flange provides direct adhesion to the acoustic panel, simplifying the assembly process while achieving superior connection strength through distributed bonding across the entire interface area.
Data Source
AI summary
The invention proposes a splitter lip for a low-pressure compressor of an axial turbomachine for an aeroplane. The splitter lip comprises an upstream annular wall made of metal with a circular leading edge, and a downstream annular partition made of an organic-matrix, short-fiber composite material. The splitter lip also supports an outer shroud for a stator upstream of the compressor. The upstream wall comprises an annular anchoring portion arranged in the thickness of the downstream partition so as to anchor the partition and the wall to one another. The anchoring portion has distributed hexagonal openings in order to increase anchoring. The invention also proposes a method for producing, by molding, a bi-material splitter lip or a mixed lip.