IBR Repair Shape Modeling for Aerodynamic and Structural Fit
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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 system and method that utilize finite element models and computational fluid dynamics to simulate structural and aerodynamic analyses of IBRs, allowing for iterative repair shape optimization and generation of repair processes that meet both structural and aerodynamic criteria, including CNC and additive manufacturing instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional geometric assessment constraints (tolerances, material removal, material addition) are applied to damaged IBRs, then repair feasibility is limited and conservative, but functional assessment constraints (aerodynamic stability, structural durability) are not considered, potentially leading to unnecessary scrapping of repairable components
Solution Approach 1:
The patent transforms the repair assessment from static geometric parameter checks to dynamic functional performance evaluation. By implementing simulation-based analysis that models aerodynamic loads, structural responses, and fatigue behavior under operating conditions, the system determines repair feasibility based on actual functional performance rather than conservative geometric tolerances. This allows damaged IBRs to be repaired and certified if they meet functional requirements, even when geometric deviations exceed traditional limits.
2Reliability
If comprehensive functional assessment simulations (aerodynamic and structural) are performed to evaluate repair options, then repair quality and safety are improved, but computational complexity and analysis time increase
Solution Approach 1:
The patent divides the comprehensive functional assessment into separate specialized simulation modules: aerodynamic analysis, structural analysis, and fatigue analysis. Each module independently evaluates specific aspects of IBR performance under operating conditions. This segmentation allows the complex assessment to be performed systematically through multiple specialized analyses rather than a single monolithic simulation, improving both computational efficiency and analytical precision.
Solution Approach 2:
The patent creates a multi-functional simulation system that can perform various types of analyses (aerodynamic, structural, fatigue) using a unified platform. The system integrates multiple physics domains and analysis methods into a single comprehensive assessment tool, enabling it to evaluate different repair scenarios across multiple performance criteria simultaneously. This universal approach streamlines the complex assessment process while maintaining thoroughness.
3Manufacturing precision
If iterative repair shape optimization is performed based on simulation data, then repair precision and performance are improved, but computational time and processing requirements increase
Solution Approach 1:
The patent performs preliminary simulation-based assessments of potential repair shapes before final manufacturing. By evaluating multiple candidate repair geometries through aerodynamic and structural simulations in advance, the system identifies optimal repair shapes that meet performance requirements. This preliminary optimization prevents unnecessary iterative adjustments during manufacturing and ensures the selected repair geometry is proven to meet functional requirements before implementation.
Data Source
AI summary
An article of manufacture may include a tangible, non-transitory computer-readable storage medium having instructions stored thereon that, in response to execution by a processor, cause the processor to perform operations comprising: 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; generating, via the processor, a first finite element model and a second finite element model based on the point cloud or the three-dimensional model, the first finite element model and the second finite element model; performing, via the processor, a structural analysis simulation with the first finite element model; performing, via the processor an aerodynamic analysis simulation with the second finite element model; iterating, via the processor, a repaired defect shape based on simulation data from the aerodynamic analysis simulation and the structural analysis simulation; and determining a repair process for the defect based on the iterating.