Hydroformed Air Intake Lip Openings With Inturned Edges
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Solution Overview
Problem
The manufacturing of air intake lips for aeronautical engine nacelles often results in 'laminarity' defects and disruptions to the aerodynamic profile due to machining for openings, which can disturb airflow, and protruding fixing members further disrupt the flow.
Innovation Solution
A method involving hydroforming with a three-dimensional die to create air intake lips or sectors with openings that have inturned edges or plunging bottoms, allowing for integral formation of these features during the manufacturing process, thereby preserving the aerodynamic profile and enabling secure fixing of add-on parts without protruding over the outer wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If openings are made by machining into the wall of the lip after forming, then add-on parts can be fixed, but laminarity defects occur which modify the aerodynamic profile and disturb the flow
Solution Approach 1:
The housing for the opening is formed during the hydroforming process itself, before the opening is cut. This preliminary formation of the housing integrated with the outer wall ensures that the aerodynamic profile is established without defects, and the subsequent opening cutting does not compromise the profile integrity
Solution Approach 2:
The housing structure is merged with the outer wall of the lip during hydroforming, creating an integral structure. This merging ensures that the housing and outer wall form a unified aerodynamic surface, eliminating laminarity defects that would occur with separate machining operations
2Strength
If fixing members are used to fix add-on parts at the level of openings, then add-on parts can be secured, but the fixing members protrude over the surface of the outer wall and disrupt the flow
Solution Approach 1:
The fixing members are nested within the housing structure that is formed during hydroforming. The housing extends under the outer wall, allowing fixing members to be positioned inside the housing rather than protruding from the outer wall surface, thus maintaining aerodynamic profile integrity while providing secure fixing
Solution Approach 2:
The housing extends in the radial direction under the outer wall, creating additional spatial dimension for fixing members. This dimensional extension allows fixing members to be positioned in a location that does not interfere with the external aerodynamic profile while still providing secure attachment
3Manufacturing precision
If the housing extends under the outer wall, then the aerodynamic profile is preserved, but the structure becomes more complex
Solution Approach 1:
The housing is merged with the outer wall through the hydroforming process, creating an integral structure rather than separate components. This merging reduces the number of parts and assembly operations, offsetting the complexity of the extended housing structure
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 ensures that the aerodynamic profile of the air intake lips or sectors is not modified during opening formation, and allows for the secure fixing of add-on parts like scoops without disrupting airflow, reducing the overall weight and maintaining the integrity of the aerodynamic flow.
Implementation Method 1
the forming of an air intake lip or an air intake lip sector by hydroforming the blank on the three-dimensional surface of the die
Data Source
AI summary
The disclosure relates to a method for manufacturing an air intake lip comprising: the arrangement of a blank facing a three-dimensional forming surface of a die of a hydroforming tool, the forming of an air intake lip preform by hydroforming the blank on the three-dimensional surface of the die, the air intake lip preform having in section a U-shape, the outer wall of the air intake lip comprising at least one hollow housing with an inturned edge and a bottom, the housing having a shape corresponding to the shape of the at least one opening cavity, the cutting of an opening in each hollow housing keeping at least the inturned edge so as to obtain an air intake lip comprising at least one opening having an edge integrally formed with the outer wall of the lip.