Integrally Bladed Rotor Repair Guided by Structural and Aerodynamic Simulation
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Solution Overview
Problem
Current repair methods for integrally bladed rotors (IBRs) in gas turbine engines are limited, as they do not consider boundary conditions, structural analysis, or aerodynamic performance, leading to unnecessary scrapping of components that could be repaired more optimally.
Innovation Solution
A system and method that involves scanning IBRs to detect defects, performing simulations to assess potential repairs, and generating repair processes that extend the life of the rotor beyond design life thresholds, while considering structural and aerodynamic criteria, and transmitting these processes to additive manufacturing or CNC machines for implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional repair methods are used for IBRs, then repair simplicity is maintained, but component life is limited and scrapping increases
Solution Approach 1:
The system performs preliminary actions by conducting comprehensive simulations (structural, aerodynamic, thermal) and boundary condition analyses before executing the repair. This includes creating digital twins, performing finite element analyses, and evaluating multiple repair scenarios in advance to determine the optimal repair approach that extends IBR life while maintaining feasibility.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring simulation results, comparing repaired IBR performance against original design specifications, and using boundary condition data from actual engine operation to refine repair approaches. This iterative feedback process ensures repairs extend component life while maintaining structural integrity and aerodynamic performance.
2Reliability
If comprehensive simulations and analyses are performed, then repair optimization is improved, but analysis time and computational resources increase
Solution Approach 1:
The comprehensive analysis system is segmented into modular components: structural analysis modules, aerodynamic analysis modules, thermal analysis modules, and boundary condition evaluation modules. Each module can be executed independently and in parallel, reducing overall analysis time while maintaining comprehensive evaluation of repair reliability through systematic division of complex analytical tasks.
3Loss of substance
If IBRs are scrapped due to defects outside product definition tolerances, then manufacturing simplicity is maintained, but material loss and cost increase
Solution Approach 1:
The system applies parameter changes by evaluating repair scenarios that modify geometric parameters, material properties, and structural configurations to accommodate defects outside original product definition tolerances. Through parametric modeling and optimization, the system determines whether defects can be repaired while maintaining acceptable performance, thereby reducing material loss and scrapping of otherwise serviceable IBRs.
Data Source
AI summary
A method can comprise receiving, via the processor, one of a point cloud and a three-dimensional model for an inspected integrally bladed rotor (IBR) and a defect including a defect shape, a defect size, and a defect location; performing, via the processor, a simulation of a rotor module in a gas turbine engine, the rotor module including the inspected IBR with a potential repaired defect; determining, via the processor, the potential repaired defect would produce an estimated life less than a design life for the inspected IBR; determining, via the processor, the estimated life would exceed a remaining life threshold for the inspected IBR; and generating, via the processor, a repair process for the potential repaired defect.