IBR Blade Repair Blend Analysis Beyond Geometric Repair Limits
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Solution Overview
Problem
Conventional repair methods for integrally bladed rotors (IBRs) in gas turbine engines are limited by geometric and material constraints, often leading to scrapping of damaged IBRs without considering functional assessments like aerodynamic stability and structural durability, thus overlooking potentially cost-effective and optimal repair options.
Innovation Solution
A method involving finite element static and modal analysis, fatigue assessment, and simulation-based repair planning to determine the feasibility of repair blend profiles exceeding traditional size thresholds, utilizing a processor-driven system for generating and analyzing digital models of inspected blades, and determining whether the repair meets deterministic criteria based on material properties and engine test data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional geometric assessment constraints are applied to repair damaged IBRs, then manufacturing precision and ease of repair are maintained, but reliability and productivity are reduced due to unnecessary scrapping of repairable components
Solution Approach 1:
The patent changes the assessment parameters from purely geometric constraints to include functional performance parameters. By implementing a comprehensive assessment system that evaluates structural durability, aerodynamic stability, and vibratory response alongside geometric constraints, the system identifies repairable IBRs that would otherwise be scrapped, thereby improving reliability without sacrificing productivity
Solution Approach 2:
The patent replaces conventional mechanical/geometric assessment methods with a computational analysis system. Using finite element analysis and performance modeling, the system substitutes traditional rule-based geometric checks with sophisticated computational evaluation of structural and functional performance, enabling more accurate identification of repairable components
2Ease of repair
If large repair blend profiles are applied to damaged IBRs, then ease of repair is improved, but manufacturing precision and reliability deteriorate due to potential aerodynamic instability and structural weakness
Solution Approach 1:
The patent implements a feedback mechanism where the computational assessment system evaluates the aerodynamic and structural consequences of proposed repair blend profiles. By analyzing the interaction between large repair profiles and engine operating conditions, the system provides feedback on whether the repair maintains acceptable aerodynamic stability and structural performance, enabling informed decisions about repair feasibility
Solution Approach 2:
The patent introduces dynamic analysis to assess the vibratory response and aerodynamic stability of repaired IBRs. By evaluating how large repair blend profiles affect the dynamic behavior of the rotor under operating conditions, the system determines whether the repair maintains acceptable performance levels, transforming static geometric constraints into dynamic performance-based assessments
3Reliability
If comprehensive functional assessment is performed on repaired IBRs, then reliability is improved, but device complexity and loss of time increase due to additional analysis requirements
Solution Approach 1:
The patent creates a universal computational assessment system that performs multiple functions: geometric constraint evaluation, structural durability analysis, aerodynamic stability assessment, and vibratory response evaluation. By consolidating these diverse assessment functions into a single integrated system, the patent reduces overall complexity while maintaining comprehensive reliability evaluation
Data Source
AI summary
A method can comprise: performing a finite element static analysis of an inspected blade of an inspected bladed rotor, the inspected blade having a repair blend profile modeled thereon, the repair blend profile exceeding a threshold repair size; performing a finite element modal analysis of the inspected blade having the repair blend profile; performing a fatigue assessment based on results from the finite element static analysis and the finite element modal analysis, the fatigue assessment including limits based on material properties of the inspected blade, the material properties based on test results at a threshold significance level; and repairing the inspected bladed rotor with the repair blend profile in response to the fatigue assessment meeting a deterministic criteria.