Split Intermediate Case for Gas Turbine Compressor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of intermediate cases for gas turbine engines is challenging due to complex shapes, high costs, and time-consuming processes, particularly in achieving the required weight, size, finish, strength, and tolerance precision.
Innovation Solution
The intermediate case is formed by combining a bleed duct created via sand casting and an IMC centerbody formed via investment casting, with the centerbody fixedly attached to the bleed duct, allowing for efficient and cost-effective production while maintaining high quality and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If intermediate case is manufactured as a single complex component, then structural integrity and shape complexity are achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The intermediate case is divided into two separate components: a bleed duct formed by sand casting and a centerbody formed by investment casting. This segmentation allows each component to be manufactured using the most appropriate process for its specific requirements, reducing overall manufacturing complexity and cost while maintaining structural integrity through subsequent assembly.
2Manufacturing precision
If intermediate case is manufactured with high precision requirements, then tolerance and finish quality are improved, but manufacturing cost and complexity increase
Solution Approach 1:
Different manufacturing processes are applied to different parts of the intermediate case based on their specific quality requirements. The centerbody, which requires high precision and smooth finish, is manufactured using investment casting. The bleed duct, which has different requirements, is manufactured using sand casting. This local quality approach optimizes manufacturing precision for each component without unnecessarily complicating the entire manufacturing process.
Data Source
AI summary
An intermediate case (IMC) for use in a compressor section of a gas turbine engine includes a bleed duct and an IMC centerbody. The bleed duct is formed via sand casting. The IMC centerbody is formed via investment casting and is fixedly attached to the bleed duct.