Split Gas Turbine Case Structure for Larger Rotor Assembly
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Solution Overview
Problem
Current gas turbine engine static structures require improvement in manufacturing and assembly methods, as they are often composed of multiple axial case segments that are pieced together, limiting the size and complexity of the rotating components and requiring cumbersome assembly processes.
Innovation Solution
A split case structure for gas turbine engines is introduced, comprising discrete case segments that form monolithic bodies, which can be additively manufactured and mechanically fastened together, allowing for larger rotor diameters and simplified assembly, with seal elements to ensure interface integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple axial case segments are used to form the static engine structure, then the structure can be assembled in a modular fashion, but the assembly process becomes cumbersome and limits the size and complexity of rotating components
Solution Approach 1:
The case structure is divided into a limited number of discrete case segments (typically two half-cases) that can be manufactured separately and then assembled. This segmentation allows for modular manufacturing while minimizing the number of joints and assembly complexity compared to using multiple small axial segments throughout the entire structure.
2Ease of manufacture
If multiple axial case segments are connected by flange connections, then the structure can be assembled from separate parts, but the structural integrity and rigidity are compromised
Solution Approach 1:
Adjacent case segments are joined by mechanically fastening them together without traditional flange connections, creating a more integrated and rigid structure. This merging approach eliminates the need for separate flanges and multiple fastening points, thereby improving structural integrity while maintaining the ability to assemble from separate manufactured parts.
3Ease of manufacture
If traditional case structures are used, then the design is simpler to manufacture with conventional methods, but larger rotor diameters and more complex designs are limited
Solution Approach 1:
The case segments are designed with varying wall thicknesses, internal features, and structural properties at different locations to optimize performance for specific design requirements. This allows the structure to accommodate larger rotor diameters and more complex internal geometries while maintaining manufacturability through targeted design features rather than uniform conventional construction.
Data Source
AI summary
An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a plurality of walls and a plurality of case segments. Each of the walls extends axially along and circumferentially about an axial centerline. The walls include a first wall and a second wall radially outboard of and axially overlapping the first wall. Each of the case segments is configured to form a respective portion of the first wall and a respective portion of the second wall. The case segments include a first case segment and a second case segment circumferentially adjacent and attached to the first case segment at a joint.