Kinetic Disassembly of Additive Support Structures via Centrifugal Force
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Solution Overview
Problem
The existing methods for removing additively manufactured support structures from complex geometries in gas turbine engines are costly and time-consuming, as they require machining, which can be difficult due to inaccessible geometries.
Innovation Solution
A rotary component design where support structures are configured to separate from rotating components using centrifugal force, with varying tensile strength and density gradients to fracture and detach during rotation, allowing for kinetic disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are removed by machining in post-processing, then support structures can be removed from additively manufactured components, but manufacturing time and cost increase considerably
Solution Approach 1:
The support structures are designed with predetermined fracture features during the additive manufacturing process itself, rather than requiring post-processing removal. The support structures are intentionally created with weakened regions that will fracture at controlled locations when subjected to centrifugal force during rotation, eliminating the need for time-consuming machining operations afterward.
Solution Approach 2:
The patent replaces the traditional mechanical machining system with a kinetic energy-based removal system. Instead of using cutting tools to mechanically remove support structures, the invention uses centrifugal force generated by rotating the component at high speed to kinetically fracture and eject the support structures from the final part.
2Ease of manufacture
If support structures are removed by machining, then support structures can be removed, but access to inaccessible geometries becomes difficult
Solution Approach 1:
The patent replaces the mechanical machining system with a kinetic energy-based removal system. Instead of using cutting tools to mechanically remove support structures, the invention uses centrifugal force generated by rotating the component at high speed to kinetically fracture and eject the support structures from the final part.
Solution Approach 2:
The support structures are designed to self-remove through their own structural characteristics. The predetermined fracture features and material property gradients are built into the support structures during additive manufacturing, allowing them to autonomously fracture and eject themselves during rotation without requiring external tooling or manual intervention.
3Productivity
If support structures are designed with varying tensile strength and density, then kinetic disassembly during rotation is enabled, but manufacturing complexity increases
Solution Approach 1:
The support structures are designed with spatially varying material properties, including regions of different tensile strength and density distributed throughout their volume. This local quality variation is achieved through additive manufacturing techniques that can deposit material with controlled properties at different locations, allowing the support structures to fracture at predetermined locations while maintaining overall structural integrity during printing.
Solution Approach 2:
The support structures utilize composite material regions with different tensile strengths and densities within a single component. These composite regions are strategically placed to create predetermined fracture paths, where weaker material zones are positioned to fail first under centrifugal loading, enabling controlled disassembly of the support structures from the final part.
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 reduces manufacturing time and costs while enabling the creation of more complex geometries by kinetically removing support structures, improving the efficiency of the manufacturing process.
Implementation Method 1
The first support structure may be configured to separate from the first structure and from the second structure in response to a centrifugal force generated by the first structure and the second structure rotating about the axis.
Implementation Method 2
a tensile strength in the first end portion of the first support structure may be less than a tensile strength in the central portion of the first support structure
Data Source
AI summary
A rotary component may comprise a first structure configured to rotate about an axis and a second structure configured to rotate about the axis. A support structure may be coupled to the first structure at a first attachment location and to the second structure at a second attachment location. The support structure may be configured to separate from the first structure and the second structure in response to a centrifugal force generated by the first structure and the second structure rotating about the axis.