Composite Turbomachine Vane Reinforced Cavity for Vibration Resistance
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Solution Overview
Problem
Turbine engine vanes made of composite material with internal cavities face issues such as reduced mechanical strength, torsional resistance, and resonance due to thin skins and large-sized cavities, leading to vibration and potential resonance with engine natural modes.
Innovation Solution
A method for manufacturing composite material vanes with a reinforced internal cavity using a core structure comprising a reinforcing structure and a sealed envelope, filled with elastomer material, which includes lattice, shell, or solid body elements to enhance mechanical strength and damp vibrations, while maintaining lightweight properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a large-sized cavity is created inside the vane to reduce mass, then the overall mass of the vane is reduced, but the mechanical strength and torsional resistance are reduced
Solution Approach 1:
The patent applies local quality by placing reinforcing structures (lattice, shells, or solid bodies) only in specific locations within the cavity where mechanical strength is needed, rather than uniformly reinforcing the entire cavity. This allows the vane to maintain low mass while having localized reinforcement at critical areas to resist bending and torsional forces.
Solution Approach 2:
The patent uses composite materials by combining the lightweight composite skin with internal reinforcing structures made of different materials (metal lattice, composite shells, or solid bodies). This creates a hybrid composite structure that leverages the advantages of different materials to achieve both low mass and high strength.
2Weight of moving object
If thin composite material skins are used to maintain low mass with a large cavity, then the mass is reduced, but the natural modes of vibration are close to engine natural modes causing resonance
Solution Approach 1:
The patent addresses vibration and resonance by introducing reinforcing structures that modify the natural frequencies of the vane skins. These structures increase the stiffness of the skins, shifting their natural modes of vibration away from the engine's operating frequencies, thereby avoiding resonance and reducing vibration risks.
Solution Approach 2:
The reinforcing structures are strategically positioned at locations where vibration and resonance are most likely to occur, such as at the roots and along the span of the vane. This localized reinforcement provides the necessary stiffness to control vibration while minimizing the overall mass increase.
3Strength
If a reinforcing structure is added inside the cavity to improve mechanical strength, then the mechanical strength and vibration resistance are improved, but the mass of the vane increases
Solution Approach 1:
The patent segments the reinforcing structure into discrete elements such as lattice structures, individual shells, or spaced solid bodies rather than using a continuous reinforcement. This segmentation reduces the amount of material needed while maintaining the necessary mechanical strength and vibration resistance.
Solution Approach 2:
The patent employs lattice structures and porous-like configurations of the reinforcing elements within the cavity. These structures provide high strength-to-weight ratios by creating a three-dimensional framework that resists loads efficiently while occupying minimal volume and adding minimal mass.
4Reliability
If a core structure with sealed envelope is used to prevent resin migration, then resin migration is prevented, but the manufacturing complexity increases
Solution Approach 1:
The sealed envelope core structure is prepared in advance before the composite skin is formed. By pre-assembling the core with its sealing envelope, the patent prevents resin migration during the composite manufacturing process without requiring complex real-time control mechanisms, thus balancing reliability with manufacturing simplicity.
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
The reinforced cavity design improves mechanical strength, reduces vibration risks, and maintains low mass, effectively damping mechanical stresses and aerodynamic forces, thus enhancing the performance and durability of composite material vanes.
Implementation Method 1
The presence of the elastomer material inside the vane enables damping of the mechanical stresses
Implementation Method 2
the volume of the remainder of the core comprises an elastomer material
Data Source
AI summary
A method for manufacturing a turbomachine vane made of composite material and having a cavity, the method includes producing a core having the shape of the cavity of the vane to be manufactured, the core including a reinforcing structure occupying only a portion of the volume of the core, the core further including a sealed envelope defining the outer surface of said core; and forming a composite material skin around the core.