Segmented Wear Member for Turbomachinery Blade Root Stress Distribution

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Solution Overview

Problem

Rotating machinery, such as turbomachinery, experiences high localized contact loads leading to wear issues in blade roots due to dry-film-lubricant coatings wearing away quickly, particularly in curved root designs, necessitating frequent and costly repairs.

Innovation Solution

A wear member with discrete portions of materials having different moduli of elasticity is placed between the anchor structure and the cavity surface of the hub, distributing contact stresses uniformly and reducing wear by using softer materials for high-stress areas and harder materials for lower-stress areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a dry-film-lubricant coating is applied to the anchor structure, then initial wear protection is provided, but the coating wears away quickly under high localized contact loads, resulting in frequent repairs

Engineering Contradiction:

Improvewear resistanceVSAvoidservice life of coating

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The wear member is divided into discrete portions with different material characteristics (softer and harder materials) positioned at specific locations to match the stress distribution pattern, with softer materials at high-stress areas and harder materials at lower-stress areas

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The wear member comprises multiple materials with different moduli of elasticity combined in a single component, allowing different regions to exhibit different wear characteristics appropriate to the local stress conditions

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a single-material wear member is used, then manufacturing is simplified, but it cannot optimally address varying stress levels across different contact areas

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwear protection effectiveness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Different portions of the wear member have different material characteristics tailored to the specific stress conditions at each location, with softer materials positioned at high-stress areas and harder materials at lower-stress areas

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The wear member is divided into discrete portions or zones with different material properties, allowing each segment to be optimized for its specific functional requirement while maintaining overall component integrity

Inventive Principle:

Principle #1Segmentation

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 wear member effectively reduces maximum contact stress, lowering wear on blade roots and mounting slots, allowing for extended maintenance intervals and reduced repair costs, and can be used in conjunction with or instead of traditional coatings.

Implementation Method 1

Methodology Applied

Scientific EffectStress distribution: Elasticity

Data Source

PatentUS10099323B2Rotating structure and a method of producing the rotating structure

Publication Date: 2018.10.16 ROLLS ROYCE CORP

AI summary

According to one aspect, a rotating structure comprises a hub having a mounting slot defined by a cavity surface and a body having an anchor structure disposed in the mounting slot. A wear member is disposed between the anchor structure and the cavity surface and the wear member has at least first and second portions of first and second material characteristics, respectively.