Rotary Separator Filter Production via 3D Model Guided Electron Beam Melting
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Solution Overview
Problem
Existing methods for producing filters for rotary air/oil separators in turbine engines result in non-uniform distribution of metal material, leading to unbalanced centrifugal inertia forces and variations in filter performance due to randomness in pore positioning, causing issues at high speeds and inconsistent behavior across different separators.
Innovation Solution
A process involving the creation of a three-dimensional mathematical model for the filter's porous structure, followed by layer-by-layer powder melting using an energy beam to form sections according to the model, ensuring uniform pore distribution and precise control over the porous structure, particularly using a titanium alloy for enhanced mechanical properties and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods using polymeric matrix or gas blowing are used to produce filter elements, then the production process is simple, but the metal material distribution is non-uniform and pore positions are random
Solution Approach 1:
The invention creates a three-dimensional digital model of the filter element with precisely defined pore positions and metal material distribution before production. This preliminary digital planning ensures that when the actual manufacturing occurs, the material can be deposited exactly where needed, achieving uniform distribution without complex physical jigs or fixtures during the process.
Solution Approach 2:
The invention replaces traditional mechanical methods (polymeric matrix manipulation, gas blowing techniques) with a digital modeling approach combined with precise material deposition. The three-dimensional model guides the entire production process, substituting mechanical complexity with computational precision to achieve uniform metal material distribution.
2Reliability
If random pore positioning is used in filter elements, then the production process is simpler, but the centrifugal inertia forces are unbalanced at high rotation speeds
Solution Approach 1:
The three-dimensional model is created with pore positions precisely calculated to ensure balanced centrifugal inertia forces before any physical production occurs. This advance planning allows the system to account for rotation dynamics and material distribution requirements, ensuring reliability at high speeds without requiring complex adjustments during manufacturing.
Solution Approach 2:
The invention changes the approach from random pore positioning to precisely controlled pore positions defined by the three-dimensional model. By adjusting and controlling the parameters of pore location, size, and distribution in the digital model, the system achieves balanced centrifugal forces while maintaining manufacturing feasibility.
3Reliability
If traditional production methods are used, then production costs are lower, but different filter elements show variations in performance at the same rotation speed
Solution Approach 1:
The three-dimensional digital model serves as a comprehensive production blueprint that ensures every filter element is manufactured with identical pore positions and metal material distribution. This preliminary digital specification eliminates variations between different filter elements, ensuring consistent performance across the entire production batch.
Solution Approach 2:
The invention replaces traditional variable mechanical production methods with a consistent digital modeling approach. The three-dimensional model provides precise guidance for material deposition, substituting mechanical variability with digital consistency to ensure that every filter element performs identically at the same rotation speed.
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 process achieves balanced and efficient filters with optimized filtering performance, maintaining stability at high speeds and ensuring consistent behavior across identical filters, while reducing production costs and time through precise control over the porous structure and material distribution.
Implementation Method 1
locally melting the powder of said layer by means of energy beam scanning in order to form a section of said porous portion
Implementation Method 2
eliminating the residual powder from the pores of the formed porous portion
Data Source
AI summary
A filter, in particular for a rotary separator, is produced using an energy beam melting process, for example an electron beam, starting from powder made from the same material as a porous filtering portion to be formed, for example from a titanium alloy; on the basis of a three-dimensional model comprising a cell structure defining the porous filtering portion, subsequent layers of powder are applied and locally melted, so as to form successive sections of the porous filtering portion; at the end of the forming process, the residual powder is evacuated from the pores.