Self-Supporting Acoustic Attenuator Layers for Additive Manufacturing
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Solution Overview
Problem
Existing 3D printing techniques for turbomachinery components, such as acoustic attenuators, face issues like geometric distortion and material wastage due to drooping, which can be mitigated by printing self-supporting layers without the need for internal supports, thereby reducing print and post-processing times.
Innovation Solution
The development of acoustic attenuators with a unitized, annular body structure featuring axially-successive cross-sectional layers and pockets that are self-supporting, allowing for additive manufacturing without internal supports, using tailored cross-sectional shapes that maintain the required volumetric footprint for effective acoustic attenuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 3D printing techniques are used to manufacture acoustic attenuators, then the manufacturing flexibility and geometric freedom are improved, but geometric distortion and material wastage occur due to drooping
Solution Approach 1:
The patent applies preliminary action by designing self-supporting cross-sectional layers with optimized geometry (apex angles between 30-60 degrees) before the printing process. This preliminary geometric design ensures that each layer supports itself during deposition, preventing drooping and maintaining geometric accuracy without requiring post-processing support structures.
Solution Approach 2:
The patent changes critical geometric parameters of the cross-sectional layers, specifically the apex angle (optimized between 30-60 degrees), layer thickness (0.05-0.2 mm), and pocket geometry. These parameter optimizations enable the layers to be self-supporting during printing, resolving the contradiction between manufacturing flexibility and geometric accuracy.
2Manufacturing precision
If internal support structures are added during additive manufacturing, then geometric accuracy is improved, but material waste and processing time increase
Solution Approach 1:
The patent implements self-service by designing cross-sectional layers that are self-supporting through optimized geometry (apex angles, pocket configurations). Each layer serves its own support function during printing, eliminating the need for separate internal support structures. This reduces material waste and simplifies post-processing while maintaining shape retention.
3Manufacturing precision
If internal support structures are added during additive manufacturing, then shape retention is improved, but print and post-processing times increase
Solution Approach 1:
The self-supporting cross-sectional layer design eliminates the need for internal support structures, which removes both the printing time required to create supports and the post-processing time required to remove them. The optimized geometry (apex angles, pocket configurations) enables each layer to support itself, significantly reducing total processing time while maintaining shape retention.
4Loss of substance
If conventional manufacturing methods are used, then material waste is reduced, but manufacturing flexibility and geometric freedom are limited
Solution Approach 1:
The patent applies segmentation by dividing the acoustic attenuator into multiple axially-successive cross-sectional layers with optimized geometries. This segmentation enables additive manufacturing flexibility while the optimized layer designs (self-supporting configurations) ensure material efficiency by eliminating unnecessary support structures. Each segment is designed to work together to achieve the final complex geometry.
Solution Approach 2:
The patent transitions from conventional 2D/3D manufacturing to 4D additive manufacturing by introducing axially-successive cross-sectional layers with varying geometries. This dimensional approach enables complex internal pocket structures and optimized acoustic pathways that would be impossible with conventional methods, while the self-supporting design maintains material efficiency.
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 enables the fabrication of acoustic attenuators with reduced material waste and processing time, achieving accurate shape retention and enhanced acoustic attenuation properties, thus minimizing noise and vibrations in turbomachinery.
Implementation Method 1
Acoustic attenuator for a turbomachine... effective acoustic attenuation properties, thus minimizing noise and vibrations in turbomachinery
Data Source
AI summary
An acoustic attenuator for a turbomachine and methodology for additively manufacturing the acoustic attenuator are provided. The acoustic attenuator includes an annular body (202) having an outer surface (204) and an inner surface (206). The inner surface of the annular body may define a bore (208) extending along a longitudinal axis (209) of the acoustic attenuator between a first end and a second end of the acoustic attenuator. The annular body may be formed by a plurality of axially-successive cross-sectional layers (e.g., 632, 634, 636) unitized between the first end and the second end of the acoustic attenuator. The plurality of axially-successive cross-sectional layers may be transversely disposed relative to the longitudinal axis of the acoustic attenuator. At least some axially-successive cross-sectional layers of the plurality of axially-successive cross-sectional layers (e.g., 632, 634, 636) defining a pocket (214) disposed between the outer surface and the inner surface of the annular body. At least a segment of a periphery of the pocket comprises two sides (1452, 1454) arranged to join at a common end point to form an apex (1460) of the pocket.