Turbine Engine Housing Bonding With External Flange Shaping
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Solution Overview
Problem
Existing manufacturing processes for aircraft turbomachine casings, particularly those made of composite materials, suffer from deformation issues during machining and bonding operations, leading to deviations from the nominal geometry, especially in the annular flanges, which are not adequately addressed by current methods.
Innovation Solution
A method involving the use of shaping tools positioned outside the casing to apply support forces in opposite axial directions on the flanges during bonding, combined with heating and pressurization, to elastically deform and correct deformations, using compact tooling that does not interfere with the bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite material manufacturing process is used, then mass is reduced and mechanical resistance is improved, but deformation occurs during extraction and machining
Solution Approach 1:
The patent applies preliminary action by pre-deforming the flanges during the bonding process using shaping tools. The flanges are elastically deformed in advance to compensate for the deformation that will occur during extraction and machining, ensuring the final geometry matches the nominal dimensions.
Solution Approach 2:
The patent implements preliminary anti-action by applying opposing forces through shaping tools during bonding to counteract the residual stresses that will cause deformation later. The tools exert forces in opposite axial directions to prevent the flange deformation that would otherwise occur during extraction.
2Ease of manufacture
If shaping tools are positioned outside the casing, then interference with bonding process is avoided, but device complexity increases
Solution Approach 1:
The patent applies dimensionality change by positioning the shaping tools in the radial direction outside the casing, rather than inside. This spatial arrangement allows the tools to apply axial forces on the flanges without interfering with the bonding process, effectively using a different dimension to resolve the conflict.
3Productivity
If flange deformation is not compensated, then manufacturing process is simpler, but machining precision deteriorates
Solution Approach 1:
The patent performs the correction action during the bonding process itself, rather than requiring separate post-processing steps. The shaping tools are applied during bonding to pre-deform the flanges, combining the correction with the manufacturing process to maintain productivity while improving precision.
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 method effectively prevents flange deformation during bonding, simplifies manufacturing, reduces the need for custom machining, and enhances mechanical and aerodynamic performance by maintaining the flanges' nominal geometry.
Implementation Method 1
exert support forces in opposite axial directions on these flanges so as to elastically deform at least one of the flanges so that the resulting displacements compensate for the deformations that will occur during step b) of bonding
Implementation Method 2
a step b) of bonding the layer to the first surface, during which the casing is heated and compressed
Implementation Method 3
a step b) of bonding the layer to the first surface, during which the casing is heated and compressed
Data Source
Figure 1~2
Figure 3~4b
Figure 5~6
AI summary
Method for manufacturing a housing (3) for an aircraft turbine engine, said housing comprising: • - an annular body (30) extending around an axis A and comprising a securing flange (31, 32) extending radially outwards at each of the axial ends thereof, and • - an abradable layer (4) arranged inside the body (30), the method comprising a step b) of bonding the layer (4) to the first surface (36), during which step the housing is heated and compressed by means of a system (19) present at least partially inside the housing (3); the method comprises, prior to step b), a step a) of mounting at least two tools (10) between the flanges (31, 32), each of the tools being located in a circumferential area (Z) outside the body (30) so as to exert bearing forces in opposite axial directions on said flanges (31, 32).