Segmented Bearing Housing Assembly for Gas Turbine Engines
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Solution Overview
Problem
Existing methods for manufacturing gas turbine engine bearing housings face challenges in meeting stringent performance, safety, and reliability requirements due to harsh temperature environments and stress/vibrational modes, with traditional manufacturing processes being time-consuming and costly.
Innovation Solution
The method involves producing segments of the bearing housing, such as the flange outer structure, intermediate structure, and main body segments using additive manufacturing, and attaching them via weldments, allowing for complex designs that meet performance and reliability criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for bearing housings, then manufacturing precision and reliability can be achieved, but manufacturing time and costs increase significantly
Solution Approach 1:
The bearing housing is divided into multiple segments that are manufactured separately using additive manufacturing and then assembled together. This segmentation allows parallel production of multiple components, significantly reducing overall manufacturing time while maintaining precision through controlled assembly processes with transition pieces.
Solution Approach 2:
The patent employs additive manufacturing technology to change the manufacturing process parameters from traditional subtractive or formative methods. This enables complex geometries to be produced directly with high precision while reducing manufacturing time, as the process builds components layer-by-layer without extensive machining operations.
2Reliability
If traditional manufacturing processes are used for bearing housings, then structural integrity can be ensured, but manufacturing costs increase
Solution Approach 1:
Dividing the bearing housing into segments enables cost-effective manufacturing by allowing additive production of complex sections that would be expensive or impossible to make with traditional methods. The segmentation reduces material waste and manufacturing complexity while maintaining structural integrity through proper joint design with transition pieces.
Solution Approach 2:
The patent utilizes additive manufacturing capabilities to create composite structures or hybrid material constructions within the bearing housing segments. This allows optimization of material properties for specific functional requirements while reducing overall material costs and improving reliability through tailored material selection in different regions of the component.
3Reliability
If complex bearing housing designs are produced using traditional methods, then performance requirements can be met, but manufacturing complexity and time increase
Solution Approach 1:
Additive manufacturing fundamentally changes the manufacturing parameters from subtractive to additive processes, enabling complex internal geometries, cooling channels, and structural features to be produced directly without complex tooling or assembly procedures. This reduces manufacturing process complexity while maintaining the ability to meet performance requirements.
Solution Approach 2:
Segmenting the complex bearing housing into manageable sections allows each segment to be manufactured using standardized additive processes, reducing overall manufacturing process complexity. The segments are then assembled using relatively simple transition pieces and joining methods, avoiding the need for extremely complex single-piece manufacturing.
4Reliability
If bearing housings are designed for specific engine configurations, then optimal performance is achieved, but adaptability across different engine types decreases
Solution Approach 1:
The segmented design with standardized transition pieces allows the bearing housing to be adapted to different engine configurations by replacing specific segments while maintaining compatible connection interfaces. This modularity enables optimization for specific engine types while preserving adaptability across different applications.
Solution Approach 2:
The patent incorporates universal connection features and standardized transition piece designs that enable the same bearing housing segments to be used across multiple engine configurations. This multi-functionality allows optimal performance for specific engines while maintaining versatility for future adaptations to different engine types.
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 reduces manufacturing time and costs while enabling the production of robust bearing housings that withstand extreme conditions, facilitating the use of common segments across different engine configurations.
Implementation Method 1
At least one of the flange outer structure segment, the intermediate structure segment, or the main body segment is produced using an additive manufacturing process
Implementation Method 2
the flange outer structure segment may be attached to the outer radial end of the intermediate structure segment by weldment and the main body segment may be attached to the inner radial end of the intermediate structure segment by weldment
Data Source
AI summary
A method of manufacturing an annular bearing housing for a gas turbine engine is provided that includes: producing a flange outer structure segment; producing an intermediate structure segment having an outer radial end, an inner radial end, a body that extends between the outer radial end and the inner radial end, and a branch member that extends outwardly from the body; producing a main body segment; attaching the flange outer structure segment to the outer radial end of the intermediate structure segment; and attaching the main body segment to the inner radial end of the intermediate structure segment. At least one of the flange outer structure segment, the intermediate structure segment, or the main body segment is produced using an additive manufacturing process.