Fan Disk Additive Manufacturing Relief Elements
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Solution Overview
Problem
Conventional manufacturing methods for fan disks in aeronautical turbine engines require large, heavy, and expensive pre-machined blanks with extensive machining cycles, resulting in significant material waste and high costs due to the need for complex shapes and high-stress materials.
Innovation Solution
The method combines forging and additive manufacturing to create a fan disk, where a simplified cylindrical shape is forged and machined, followed by additive manufacturing to add relief elements such as studs and ferrules, reducing the size and material waste of the initial blank and enabling the use of materials with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods (milling machine, lathe) are used to produce the fan disk from a large blank, then the disk can be manufactured with required strength and reliability, but the blank size and weight increase significantly, leading to higher material waste and manufacturing cost
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forging the main cylindrical body, machining to obtain the second cylindrical shape, and adding relief elements through additive manufacturing. This segmentation allows each stage to optimize for its specific function, reducing overall material waste
Solution Approach 2:
The invention changes the manufacturing parameters by introducing additive manufacturing for relief elements instead of traditional subtractive machining. This parameter change enables precise material deposition only where needed, significantly reducing material waste and blank size requirements
2Ease of manufacture
If a large blank encompassing the entire part is used for conventional machining, then all relief parts can be machined from the same blank, but the machining cycle extends and chip loss increases, resulting in substantial material waste and high manufacturing cost
Solution Approach 1:
The invention merges different manufacturing techniques (forging, machining, and additive manufacturing) into a single integrated process. This combination allows the main body to be forged efficiently while relief elements are added through additive manufacturing, eliminating the need for extensive machining and reducing material waste
Solution Approach 2:
The relief elements are added through additive manufacturing after the main cylindrical shape is forged and machined. This preliminary action of creating the base structure first, then adding features as needed, avoids the need to include all features in the initial large blank, thereby reducing material waste
3Manufacturing precision
If conventional machining methods are used to create complex relief elements like studs and ferrules, then the parts can be manufactured with required precision, but the machining complexity and time increase substantially
Solution Approach 1:
The invention replaces traditional mechanical machining methods with additive manufacturing for creating relief elements. This substitution eliminates complex machining operations while maintaining manufacturing precision, as additive manufacturing can directly create complex geometries without extensive tooling and machining cycles
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 approach reduces manufacturing costs, minimizes material loss, and allows for the creation of complex shapes that cannot be achieved with conventional methods, enabling lighter, more efficient, and cost-effective production of fan disks with improved material properties.
Implementation Method 1
a step of adding by additive manufacturing at least one relief element to the second cylindrical shape
Implementation Method 2
a step of forging a first cylindrical shape of axis X
Data Source
AI summary
A method for manufacturing a fan disk of a turbine engine includes forging a first cylindrical shape of axis X, machining the first cylindrical shape to obtain a second cylindrical shape, adding by additive manufacturing at least one relief clement to the second cylindrical shape.