Ribbed Multi-Cover Airfoil Structure for Lightweight Fan Blades
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Solution Overview
Problem
Existing gas turbine engine components, particularly hollow fan blades, face challenges in weight reduction and structural integrity due to the need for robust construction methods that balance aerodynamic performance with material efficiency.
Innovation Solution
The design incorporates a recessed region in the airfoil body with ribs dividing it into pockets, which are enclosed by cover skins formed from a common cover, allowing for a lightweight yet rigid structure through welding and strategic placement of localized and peripheral cover skins, reducing material usage and enhancing fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If robust construction methods are used to ensure structural integrity, then strength is improved, but weight increases
Solution Approach 1:
The airfoil body is divided into multiple pockets by internal ribs, with each pocket enclosed by separate cover skins. This segmentation allows for optimized material distribution, creating a lightweight structure that maintains structural integrity through the distributed rib-pocket-skin architecture rather than requiring solid robust construction
Solution Approach 2:
The airfoil employs a composite construction combining the airfoil body, internal ribs, and cover skins to create a multi-layered structure. This composite approach enables weight reduction while maintaining strength, as each component can be optimized for its specific function and the combined structure provides enhanced structural integrity compared to a single-material construction
2Weight of moving object
If material usage is reduced to decrease weight, then weight is improved, but structural integrity deteriorates
Solution Approach 1:
Material is strategically distributed throughout the airfoil structure with ribs positioned to provide local reinforcement at critical stress points and cover skins enclosing specific pockets. This local quality approach ensures that material is placed only where structurally necessary, reducing overall weight while maintaining integrity through targeted reinforcement rather than uniform material distribution
Solution Approach 2:
The segmentation into ribs and pockets creates a framework that provides structural integrity with minimal material. The ribs act as internal support structures that distribute loads, allowing the cover skins to be thinner and lighter while maintaining overall structural strength through the distributed rib framework
3Strength
If multiple cover skins are used to enclose pockets, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The airfoil is segmented into multiple pockets, each enclosed by cover skins, creating a modular structure. This segmentation provides structural benefits through distributed reinforcement while the modular nature of the pockets and cover skins simplifies the construction process, as each pocket can be independently formed and assembled
Solution Approach 2:
The ribs are formed as integral portions of the airfoil body in advance, creating pre-positioned support structures that guide the subsequent attachment of cover skins. This preliminary action simplifies the overall construction process by establishing the structural framework before adding the enclosing cover skins, reducing construction complexity while maintaining structural integrity
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 approach results in a lighter, more efficient gas turbine engine component with improved structural integrity and reduced stress concentrations, enhancing the engine's overall performance and durability.
Implementation Method 1
A plurality of cover skins are welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets
Data Source
AI summary
An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body extending between leading and trailing edges and extending from a root section, and the airfoil body defining pressure and suction sides. The airfoil body defines a recessed region extending inwardly from at least one of the pressure and suction sides, and the airfoil body includes one or more ribs that define a plurality of pockets within a perimeter of the recessed region. A plurality of cover skins is welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets. The plurality of cover skins are formed from a common cover having a perimeter that is dimensioned to mate with the perimeter of the recess.