Fan Blade Cavity Filler Compression Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual process of applying and flattening low density filler in fan blades of gas turbine engines is labor-intensive due to variations in manufacturing processes, requiring manual pressure adjustment and tapping to achieve a smooth surface for bonding.
Innovation Solution
A method involving the application of adhesive in cavities, placement of low density filler, partial curing under pressure using a press with matching dies, and compression to achieve a flush surface, utilizing urethane adhesive and aluminum foam fillers to reduce weight while ensuring a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual pressure application and tapping is used to flatten low density filler, then the filler surface can be made flush with the blade body surface, but the process becomes labor intensive and reduces productivity
Solution Approach 1:
The patent replaces the manual mechanical process of pressing and tapping with a mechanical press system that automatically applies controlled pressure to compress the low density filler to the desired thickness, eliminating manual labor while maintaining surface flatness
Solution Approach 2:
The patent controls the compression pressure and duration parameters through the press system to achieve the desired filler thickness and surface flatness, replacing manual parameter adjustment with controlled mechanical parameters
2Shape
If manual tapping is used to compress high spots of low density filler, then surface uniformity is achieved, but the process requires significant operator time and effort
Solution Approach 1:
The patent substitutes the manual tapping operation with a mechanical press that applies distributed pressure across the entire filler surface, achieving uniform compression and surface flatness without requiring operator time for manual adjustments
Solution Approach 2:
The press system applies compression pressure before final bonding, pre-flattening the low density filler surface to ensure uniform contact and eliminate the need for post-compression adjustments
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 method automates the process, reducing labor and ensuring a smooth, flush surface for bonding, thereby enhancing the efficiency and robustness of the bonding process while maintaining weight reduction and cost savings.
Implementation Method 1
applying an adhesive in a cavity
Implementation Method 2
partially curing an adhesive during the step of applying pressure
Implementation Method 3
applying pressure to the inner exposed surface of the fan blade body with an upper die of the press to compress the plurality of pieces of low density filler
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of forming a fan blade (62) includes the step of positioning a piece of low density filler (72) in a cavity (66) of an inner exposed surface (70) of a fan blade body (64). An upper surface (98) of the piece of low density filler (72) is located above the inner exposed surface (70) of the fan blade body (64), and the low density filler (72) has a density lower than a density of a material of the fan blade body (64). The method further includes the steps of positioning the fan blade body (64) in a lower die (90) of a press (88) and applying pressure to the inner exposed surface (70) of the fan blade body (64) with an upper die (92) of the press (88) to compress the low density filler (72) such that the upper surface (98) of the piece of low density filler (72) is approximately flush with the inner exposed surface (70) of the fan blade body (64).