Engine Component Stiffening Patterns via Local Burnishing

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Solution Overview

Problem

Existing methods for manufacturing gas turbine engine components, such as isogrid structures, face challenges including difficulty in forming cylindrical shapes using additive manufacturing, need for extensive post-processing machining, and adverse aerodynamic effects due to protruding ribs.

Innovation Solution

The implementation of stiffening patterns in unit cell structures, featuring pairs of alternating recessed and protruding trigonal unit cells, increases the moment of inertia and isotropic stiffness of the structure, allowing for easier manufacturing using additive techniques and reduced aerodynamic disturbance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional additive manufacturing is used to manufacture gas turbine engine components, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to difficulty in forming cylindrical shapes

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidcylindrical shape accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The component is divided into multiple segments or zones with different geometric features. Cylindrical sections are manufactured using traditional machining methods while other sections can utilize additive manufacturing, allowing each segment to be optimized for its specific manufacturing process and geometric requirements

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines multiple manufacturing methods (additive manufacturing and traditional machining) into a hybrid manufacturing approach. This allows the component to benefit from both the flexibility of additive manufacturing and the precision of traditional machining for cylindrical shapes

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If extensive post-processing machining is applied to achieve precise cylindrical shapes, then manufacturing precision is improved, but productivity deteriorates due to increased processing time

Engineering Contradiction:

Improvecylindrical shape accuracyVSAvoidmanufacturing throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Cylindrical sections and critical geometric features are pre-formed using traditional machining methods during the initial manufacturing stage, rather than requiring extensive post-processing. This preliminary action ensures precision is built-in from the start, reducing or eliminating the need for time-consuming post-processing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional machining is applied only to specific local regions where cylindrical precision is critical, while other regions utilize additive manufacturing. This localized application of machining minimizes the total amount of post-processing required while maintaining precision where needed

Inventive Principle:

Principle #3Local quality

3Strength

If protruding ribs are used in isogrid structures to increase stiffness, then structural strength is improved, but aerodynamic performance deteriorates due to adverse aerodynamic effects

Engineering Contradiction:

Improvestructural stiffnessVSAvoidaerodynamic disturbance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Instead of using protruding ribs that extend outward from the surface, the invention uses recessed ribs or grooves that are indented into the surface. This inverted approach maintains the structural stiffening function while eliminating the protruding geometry that causes aerodynamic disturbance

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The stiffening structure uses recessed features that are localized and integrated into the surface, creating minimal aerodynamic disturbance while providing sufficient structural reinforcement. The local geometric modifications maintain strength without creating large-scale protrusions

Inventive Principle:

Principle #3Local quality

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 stiffening patterns enhance the structural stiffness and resistance to bending and buckling, while enabling the manufacture of complex shapes like cylindrical structures with reduced weight and improved aerodynamic performance.

Implementation Method 1

a tool to apply an operation to the material between the tool and the support structure to form the recessed and protruding unit cells

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20250178141A1Local low plasticity burnishing for manufacture of engine components with complex organic stiffening patterns

Publication Date: 2025.06.05 GENERAL ELECTRIC CO

AI summary

Methods, apparatus, systems and articles of manufacture are disclosed for a framework and associated process to form an engine component. Examples provide localized, low plasticity burnishing or deformation to form complex, organic stiffening patterns. An example apparatus includes a frame to hold a part; a tool to apply a force to the part; and a support structure to be positioned opposite the tool to support the part when the force is applied to the part by the tool.