Axisymmetrical Intermediate Case Insert for Wear Compensation
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Solution Overview
Problem
The axisymmetrical portion of an aircraft turbojet engine's intermediate case experiences irregular wear due to operational stresses and vibrations, leading to the need for frequent repairs, which are currently impractical without disassembling the component.
Innovation Solution
Incorporating radially open annular inserts made of wear-resistant materials like INCONEL, which can be easily disassembled and replaced within the annular groove, with complementary ribs and adhesive bonding for secure positioning, allowing for on-site repairs without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the groove is made in the axisymmetrical portion, then the lip can bear against the groove to support the thrust reverser cowl, but the groove walls experience irregular wear due to operational stresses and vibrations
Solution Approach 1:
The groove is divided into two functional parts: a structural groove in the axisymmetrical portion and a removable insert that lines the groove. The insert can be segmented into multiple pieces if needed and replaced independently without replacing the entire axisymmetrical portion, allowing wear compensation while maintaining the support function.
Solution Approach 2:
The insert is made from material with different wear properties than the axisymmetrical portion. By changing the material parameter (using wear-resistant material for the insert), the groove maintains its structural function while the insert absorbs the wear, extending the overall component life.
2Reliability
If the groove walls wear beyond a predefined limit, then the axisymmetrical portion must be repaired or stored, but current repair techniques require disassembly or sanding operations
Solution Approach 1:
The wear-prone surface (insert) is extracted as a separate removable component from the axisymmetrical portion. When wear occurs, only the insert needs to be removed and replaced, not the entire axisymmetrical portion. This extraction principle enables easy on-site repair without disassembly of the main component.
Solution Approach 2:
The insert is designed as a consumable component that can be easily replaced when worn. Instead of repairing or replacing the expensive axisymmetrical portion, a relatively simple and inexpensive insert is swapped out, enabling cost-effective and quick maintenance operations.
3Ease of repair
If the insert is laid out inside the groove to cover the internal faces, then wear compensation becomes possible, but the insert requires positioning and securing mechanisms
Solution Approach 1:
The insert includes pre-formed positioning features (protrusions fitting into recesses, or keyways) that are prepared in advance during insert manufacturing. When the insert is installed in the groove, these pre-prepared features automatically align and secure the insert without requiring complex positioning operations during maintenance, simplifying the repair process.
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
Enables effective compensation for wear and extends the lifespan of the axisymmetrical portion by facilitating easy and efficient on-site repairs, reducing downtime and maintenance costs.
Implementation Method 1
the insert is adhesively bonded inside the groove
Data Source
AI summary
An axisymmetrical portion for an aircraft turbojet engine intermediate case intended to protrude downstream from an outer axisymmetrical portion of the intermediate case is provided. The axisymmetrical portion includes an annular groove radially open outwards, and at least one insert laid out inside the groove, which covers each internal face of the groove and which is radially open outwards.