Hollow Vane Cover Ply Structure for Vibration Tailoring
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Solution Overview
Problem
Hollow vanes used in engines face challenges in meeting dimensional and material requirements due to limitations in casting processes, which affect their vibratory characteristics and adaptability for different operating conditions.
Innovation Solution
A process involving forming an open body with a cover support structure, attaching a cover with plies to form flow passages, and brazing, which includes using dampener materials and additive/subtractive processes to modify vibratory characteristics and stiffness in response to aerodynamic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hollow vanes are manufactured by casting with internal cores, then a hollow cavity is formed within the cast part, but the casting process cannot meet the dimensional and material requirements demanded by the engine operating environment
Solution Approach 1:
The vane is divided into two separate components: an open body and a cover. The open body is formed by casting with a core to create the hollow cavity, while the cover is separately manufactured to precise dimensional tolerances and then attached to the open body. This segmentation allows each component to be optimized for its specific manufacturing requirements.
Solution Approach 2:
A cover is introduced as an intermediary component that attaches to the cast open body. The cover serves as a mediator that provides the precise dimensional control and material properties required for engine operation, while the cast open body provides the hollow cavity structure. The cover acts as the interface between the casting process and the final precision requirements.
2Adaptability or versatility
If a cover is attached to the open body to form flow passages, then the vibratory characteristics can be tailored, but the structural complexity increases
Solution Approach 1:
Ply materials are applied locally to specific areas of the cover to modify vibratory characteristics. Rather than requiring the entire cover structure to be complex, the damping plies are strategically placed in locations where vibration control is needed, providing local quality enhancement without overall structural complexity.
Solution Approach 2:
The cover is constructed using composite materials, combining a base cover material with ply materials (such as damping materials) that are attached to the cover surface. This composite construction allows the cover to provide both the structural function of forming flow passages and the vibratory control function through the ply materials, achieving adaptability without excessive complexity.
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 allows for tailored vibratory characteristics and enhanced stiffness of the hollow vane assembly, optimizing its performance across various engine operating conditions and extending the life of engine components by managing stress and fatigue.
Implementation Method 1
disposing a dampener material between an outer layer and an inner layer of the cover to form the at least one ply in the cover
Implementation Method 2
disposing a dampener material between an outer layer and an inner layer of the cover to form the at least one ply in the cover
Implementation Method 3
brazing the cover to the open body
Data Source
Figure 1
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AI summary
A process of tailoring vibratory characteristics of a cover (64) for an open body (62) hollow vane assembly (60) comprises forming the open body, the open body including an interior (78), forming at least one cover support structure (66) in said open body proximate the interior, forming a cover (64), the cover being configured to attach to the open body to form at least one flow passage, forming at least one ply (94) in the cover (64) and brazing the cover to the open body. A hollow vane assembly comprises an open body including an interior, at least one cover support structure formed in said open body proximate the interior, a cover brazed to the open body to form at least one flow passage and at least one ply formed in the cover. A process for modifying a vibratory characteristic of a cover to an open body comprise forming an open body, the open body including a leading edge (80) opposite a trailing edge (82), the open body including a pressure side (86) and a suction side (84) opposite the pressure side, the open body including an interior, forming a cover, the cover being configured to couple with the open body proximate the pressure side to form at least one flow passage, forming at least one ply in the cover and attaching the cover to the open body.