Cooled Mounting Plate Assembly for Gas Turbine Die Forming
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Solution Overview
Problem
Existing methods for forming gas turbine engine components do not effectively manage heat exchange and cooling during the high-temperature forming process, which can lead to thermal stresses and inefficiencies in component deformation.
Innovation Solution
A mounting plate with an internal cooling circuit and a die assembly that includes a pair of structural plates, forming dies, and mounting plates with integrated cooling circuits, allowing for efficient heat management and temperature control during the forming process by circulating coolant through the circuits and using fins to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high temperature is used for forming gas turbine engine components, then the deformation process is improved, but thermal stresses and heat management become problematic
Solution Approach 1:
The cooling system is segmented into multiple independent circuits (first cooling circuit and second cooling circuit) that are fluidly isolated from each other within the mounting plate. This allows different regions to be cooled independently, enabling precise temperature control during the high-temperature forming process while managing thermal stresses effectively.
Solution Approach 2:
The cooling circuits incorporate fins in the intermediate portion that follow the perimeter of the abutment, providing enhanced local heat transfer capacity where it is most needed. The fins extend partially from the first sidewall towards the second sidewall, creating localized cooling zones that address thermal stresses at critical interfaces between the mounting plate and forming die.
2Temperature
If cooling circuits are added to manage heat, then temperature control is improved, but device complexity increases
Solution Approach 1:
Multiple cooling circuits are merged into a single mounting plate structure, with the first and second cooling circuits integrated into the plate body. This consolidation provides efficient temperature control while avoiding the complexity of separate cooling devices for each mounting plate, as the circuits share common inlet and outlet ports.
Solution Approach 2:
The mounting plate serves multiple functions: it provides structural support for the forming die, enables temperature control through integrated cooling circuits, and manages thermal stresses through fin-enhanced heat transfer. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
3Loss of energy
If fins are added to enhance heat transfer, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The fins are created by changing the geometric parameters of the mounting plate during manufacturing. By incorporating the fins into the intermediate portion of the cooling circuits that follow the abutment perimeter, the design utilizes parameter changes in the plate body geometry to achieve enhanced heat transfer without requiring separate fin components or complex assembly steps.
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 solution enables precise temperature control and reduced thermal stresses, improving the deformation process and quality of gas turbine engine components by maintaining the temperature of the forming dies and mounting plates within a predetermined threshold, thus enhancing the structural integrity and performance of the components.
Implementation Method 1
communicating fluid to the passageway to decrease a temperature of the mounting plate
Implementation Method 2
efficient heat management and temperature control during the forming process by circulating coolant through the circuits
Implementation Method 3
using fins to enhance heat transfer
Implementation Method 4
The intermediate portion includes a plurality of fins extending partially from a first sidewall towards a second sidewall opposed to the first sidewall
Data Source
Figure 1
Figure 2
Figure 3~7
AI summary
A mounting plate (280) for forming a gas turbine engine component (160) comprising a plate body (280A) defining an abutment (280E) dimensioned to mate with a forming die (182, 183). The plate body (280A) defines at least one internal cooling circuit (288). The at least one internal cooling circuit (288) includes a passageway (289) having an intermediate portion (289C) interconnecting inlet and outlet portions (289A, 289B). The intermediate portion (289C) is dimensioned to follow a perimeter of the abutment (280E). The intermediate portion (289C) includes a plurality of fins (290) extending partially from a first sidewall (280F) towards a second sidewall (280G) opposed to the first sidewall (280F). A method of forming a gas turbine engine component (160) is also disclosed.