Parametric Component Design for Gas Turbine Engine Manufacturing
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Solution Overview
Problem
Manufacturing variations in gas turbine engine components, such as airfoils, often result in unacceptable components due to shifts, tilts, shrinks, bends, and twists, leading to high rework or scrap rates, as existing methods struggle to accurately predict and mitigate these deviations.
Innovation Solution
A computer-aided design process that defines variation mode parameters, constructs a parametric model to simulate and compare expected output components to as-manufactured ones, adjusts manufacturing processes to reduce undesirable variations, and verifies functional acceptance through mesh morphing and structural analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for gas turbine engine components, then production efficiency is maintained, but manufacturing variations (shifts, tilts, wall thickness variations) result in high numbers of unacceptable components requiring rework or scrap
Solution Approach 1:
The patent applies preliminary action by performing forming simulations and predicting manufacturing variations before actual production. The system pre-calculates expected deviations in component geometry (shifts, tilts, wall thickness variations) and adjusts forming parameters in advance to compensate for anticipated variations, thereby reducing the number of unacceptable components before they are manufactured.
Solution Approach 2:
The patent implements feedback by comparing predicted manufacturing variations with actual measurements from previously manufactured components. The system continuously refines its prediction models based on measured data from real parts, improving the accuracy of variation predictions and enabling better pre-compensation for manufacturing deviations.
2Manufacturing precision
If manufacturing processes are adjusted to reduce variations, then component accuracy improves, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent replaces complex mechanical trial-and-error adjustment processes with computational simulation and prediction systems. Instead of physically adjusting forming parameters through repeated testing, the system uses software-based forming simulations to predict variations and calculate optimal forming parameters, thereby reducing physical process complexity while improving precision.
Solution Approach 2:
The patent creates virtual copies of the manufacturing process through detailed forming simulations that replicate the physical forming behavior. These digital twins allow engineers to test and optimize forming parameters in the virtual environment before applying them to actual production, avoiding the need for multiple physical trial runs and reducing overall process complexity.
3Adaptability or versatility
If multiple variations in component geometry are allowed, then manufacturing flexibility is maintained, but the number of unacceptable components increases
Solution Approach 1:
The patent systematically varies forming parameters in simulations to understand their impact on component geometry variations. By analyzing how different parameters (forming pressure, temperature, timing) affect specific geometric features, the system identifies optimal parameter combinations that maintain manufacturing flexibility while ensuring components meet geometric tolerance requirements.
Data Source
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AI summary
A method for implementing a component design model includes defining a component design specification, defining at least one variation mode parameter of a component manufacturing process (210), constructing a parametric model relating the at least one variation mode parameter (220) to the component design specification, determining an expected component output based on the parametric model (230) and comparing the expected component output to at least one as-manufactured component (240), and defining the parametric model as accurate in response to the expected output component matching the at least one as-manufactured component within a predefined degree of accuracy.