Hollow Fan Blade Cover Skin Structure for Weight and Strength
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Solution Overview
Problem
Hollow gas turbine engine components, particularly fan blades, face challenges in achieving optimal structural integrity and weight reduction while maintaining aerodynamic efficiency and durability.
Innovation Solution
The design incorporates a recessed region in the airfoil body with ribs dividing it into pockets, which are enclosed by cover skins formed from a common cover, including a peripheral and localized cover skins, welded along the ribs to provide a continuous surface and enhance structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If hollow fan blades are constructed by attaching a cover to an airfoil body, then weight reduction is achieved, but structural integrity and durability are compromised
Solution Approach 1:
The cover is segmented into multiple cover skins that are selectively positioned and attached to different portions of the airfoil body. This segmentation allows for optimized weight reduction while maintaining structural integrity through distributed attachment points along the leading edge, trailing edge, and spanwise directions.
Solution Approach 2:
Different regions of the airfoil body receive different numbers and types of cover skins based on local structural requirements. Areas requiring higher strength receive multiple overlapping cover skins, while less critical areas receive fewer cover skins, optimizing the balance between weight reduction and structural integrity.
2Strength
If multiple cover skins are attached to the airfoil body, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The cover system is divided into multiple independent cover skins that can be manufactured separately and then attached to the airfoil body in a modular fashion, simplifying the manufacturing process while maintaining structural integrity.
Solution Approach 2:
Multiple cover skins are positioned in overlapping relationships where they nest together along the airfoil body, creating a layered structure that enhances strength while using standardized attachment procedures for each layer.
3Strength
If cover skins are welded along ribs to enclose pockets, then structural support is enhanced, but stress concentrations may increase
Solution Approach 1:
Ribs are strategically positioned at specific locations where structural support is most needed, such as along the leading edge, trailing edge, and spanwise directions. This localized rib placement provides targeted structural reinforcement while minimizing the overall number of welds and potential stress concentration points.
Solution Approach 2:
The structural support system is segmented into multiple ribs distributed throughout the airfoil body, each providing localized reinforcement. This segmentation distributes stress more evenly compared to a single continuous support structure, reducing peak stress concentrations.
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 configuration reduces weight, improves structural integrity, and maintains aerodynamic efficiency by allowing the airfoil to flex and absorb impacts, while reducing stress concentrations and material usage.
Implementation Method 1
A plurality of cover skins are welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets
Data Source
AI summary
An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body extending between leading and trailing edges in a chordwise direction and extending from a root section in a spanwise direction, and the airfoil body defining pressure and suction sides separated in a thickness direction. The airfoil body defines a recessed region extending inwardly from at least one of the pressure and suction sides, and the airfoil body includes one or more ribs that define a plurality of pockets within a perimeter of the recessed region. A plurality of cover skins is welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets. The plurality of cover skins formed from a common cover having a perimeter that is dimensioned to mate with the perimeter of the recess. A method of forming a gas turbine engine component is also disclosed.