Spinner Return Flange Foreign Object Strike Resistance
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Solution Overview
Problem
Existing gas turbine engine spinners face challenges in providing adequate resistance to foreign object strikes, such as bird strikes, while minimizing material and weight costs, as current solutions like metallic rings add unnecessary weight and cost.
Innovation Solution
The design incorporates a return flange formed using a compression moulding process with an internal geometric support, such as a gusset plate, to enhance resistance and stiffness, and a forward flange that interfaces with the nosecap to limit extension, allowing for improved durability without excessive weight or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic ring is used to replace the return flange, then foreign object resistance is improved, but weight and production cost increase
Solution Approach 1:
The patent changes the material parameters from metallic to composite materials, achieving adequate foreign object resistance while significantly reducing weight. The composite return flange is designed with appropriate fiber orientation and material selection to meet FAA regulations without the excess weight of metallic rings.
Solution Approach 2:
The patent employs composite materials for the return flange instead of metallic rings. The composite construction provides the necessary strength and foreign object damage resistance while reducing weight, aligning with the goal of avoiding prohibitive excess weight addition to the spinner.
2Reliability
If a metallic ring is used to replace the return flange, then foreign object resistance is improved, but production cost increases
Solution Approach 1:
The patent changes the material and manufacturing parameters from metallic fabrication to composite material processes, achieving cost reduction while maintaining foreign object resistance. The composite return flange can be manufactured more economically than metallic rings while meeting FAA regulations.
Solution Approach 2:
The patent adopts composite materials and manufacturing processes that are more cost-effective compared to metallic rings. The composite return flange provides the necessary durability at lower production cost, avoiding the unnecessary cost of metallic rings.
3Reliability
If the forward flange extends further forward, then foreign object resistance is improved, but structural stiffness decreases
Solution Approach 1:
The patent applies local quality by varying the thickness and fiber orientation of the composite return flange in different regions. The forward flange is designed with optimized local properties that provide adequate foreign object resistance at the extension point while maintaining overall structural stiffness through strategic reinforcement.
Solution Approach 2:
The patent solves the stiffness problem by adding geometric supports (gusset plates) that create a three-dimensional structural framework. This dimensional addition provides structural reinforcement without requiring the forward flange to extend further forward, thereby maintaining stiffness while achieving adequate foreign object resistance.
4Reliability
If more material is used to enhance resistance, then foreign object resistance is improved, but weight increases
Solution Approach 1:
The patent uses composite materials with high strength-to-weight ratio to achieve adequate foreign object resistance without proportionally increasing weight. The composite construction allows for optimized material distribution that provides necessary protection while minimizing weight penalty compared to conventional metallic solutions.
Solution Approach 2:
The patent changes the material parameters to composite materials that provide superior specific strength and stiffness. This parameter change enables achieving the required foreign object resistance levels with less material mass compared to metallic alternatives, thereby reducing overall spinner weight.
Data Source
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AI summary
A spinner (15) for a fan assembly (11) of a gas turbine engine (10), a method of fabricating a spinner for a fan assembly (11) of a gas turbine engine (10), and a gas turbine engine (10) are disclosed. The fan section (11) may include a nosecap (25). The spinner (15) may include a forward end (17), an aft end (18), and a return flange (30) associated with the forward end (17). The return flange (30) may include a forward flange (34) extending forward towards the nosecap (25) and an aft flange (32) extending aft towards the aft end (18).