Reversed-Cone Turbine Exhaust Case for Support-Free 3D Printing
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Solution Overview
Problem
Existing additive manufacturing processes for turbine exhaust cases face limitations such as the need for extensive support structures, which increase time and cost due to the use of additional material and the 45° rule for overhanging features, and traditional manufacturing methods lack the flexibility to create complex geometries efficiently.
Innovation Solution
A turbine exhaust case design utilizing an additive manufacturing process, specifically laser powder bed fusion, that minimizes the use of support structures by incorporating a reversed cone end and flexible bends, allowing for a single, monolithic component with reduced material usage and faster manufacturing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional additive manufacturing processes are used to manufacture turbine exhaust cases, then complex geometries can be created, but extensive support structures are required which increase manufacturing time and cost
Solution Approach 1:
The patent applies the inversion principle by reversing the traditional cone orientation in the exhaust case design. Instead of a conventional cone shape that would require extensive support structures during additive manufacturing, the design uses a reversed cone configuration that allows the overhanging surfaces to naturally support themselves during the build process, thereby minimizing or eliminating the need for support structures and reducing manufacturing time
Solution Approach 2:
The patent employs parameter changes by modifying the geometric parameters of the exhaust case, specifically the cone angle and orientation. By changing the cone angle to a reversed configuration, the design achieves complex geometries while the altered parameters allow the structure to be self-supporting during additive manufacturing, eliminating the need for extensive support structures
2Shape
If traditional additive manufacturing processes are used to manufacture turbine exhaust cases, then complex geometries can be created, but extensive support structures are required which increase material usage and cost
Solution Approach 1:
The reversed cone design inverts the traditional geometry to eliminate the need for support structures, thereby preventing material waste. The reversed configuration allows the overhanging surfaces to support themselves during additive manufacturing, eliminating the additional material that would otherwise be consumed by support structures
Solution Approach 2:
The patent extracts and eliminates the unnecessary support structure components from the additive manufacturing process. By designing the reversed cone geometry that requires minimal or no support structures, the invention removes the source of material waste and reduces overall material consumption while maintaining the ability to create complex geometries
3Strength
If rigid structures are used in turbine exhaust cases, then structural strength is maintained, but thermal stresses increase
Solution Approach 1:
The patent incorporates flexible bends into the exhaust case design, creating flexible regions that can accommodate thermal expansion and contraction. These flexible sections act as stress-relief zones that maintain overall structural integrity while reducing thermal stresses, allowing the structure to adapt to temperature variations without compromising strength
4Productivity
If traditional manufacturing methods are used, then production time is reasonable, but flexibility to create complex geometries is limited
Solution Approach 1:
The reversed cone design leverages additive manufacturing capabilities to create complex geometries that would be difficult or impossible to produce with traditional manufacturing methods. The inverted geometry is specifically optimized for additive manufacturing, allowing complex shapes to be produced efficiently without the need for multiple assembly steps or specialized tooling, thereby maintaining productivity while greatly enhancing geometric flexibility
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
The design enables faster production, lower costs, and reduced weight by minimizing support structure requirements, while enabling complex geometries that traditional methods cannot achieve, and reduces thermal stresses through flexible bends.
Implementation Method 1
additive manufacturing process, specifically laser powder bed fusion
Implementation Method 2
laser powder bed fusion process
Data Source
AI summary
A turbine exhaust case is disclosed herein. The turbine exhaust case including an outer shroud having a cylindrical shape and extending in a first direction parallel to a center of axis and extending circumferentially around the center axis, an inner shroud having frustoconical shape, the inner shroud disposed within the outer shroud, the inner shroud extending circumferentially around the center axis, a plurality of struts coupled to the outer shroud and the inner shroud, an inner cone having a frustoconical shape, the inner cone coupled to and extending into the inner shroud, the inner cone extending circumferentially around the center axis, the inner cone tapering at a first angle with respect to the center axis, the first end of the inner cone being coupled to the second end of the inner shroud, and a flat surface coupled the second end of the inner cone.