Static Vane Ring Fillet Radius Stress Reduction
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Solution Overview
Problem
Existing static vane rings in gas turbine engines experience high stresses at the junction of struts and duct walls due to uncontrolled fillet radii and sharp corners from welding, which can lead to structural integrity issues.
Innovation Solution
A static vane ring design featuring radially extending struts with enlarged sections and controlled fillet radii, where the enlarged sections are integrated with the duct walls to form a smooth, aerodynamic profile, reducing stress concentrations by providing a more controlled fillet radius and avoiding sharp corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If struts are directly welded to duct walls with conventional welding, then manufacturing is simple, but high stresses occur at the junction due to uncontrolled fillet radii and sharp corners
Solution Approach 1:
The strut end is designed with a large radius of curvature (enlarged section) that smoothly transitions into the duct wall, eliminating sharp corners and reducing stress concentrations. This curved geometry is integrated into the strut fabrication process, allowing the enlarged section to be formed as part of the strut body before welding, thereby maintaining manufacturing simplicity while significantly improving structural strength at the junction.
Solution Approach 2:
The invention changes the geometric parameters of the strut end by introducing an enlarged section with a specific radius of curvature. This parameter modification transforms the stress distribution pattern at the strut-duct wall junction, reducing peak stresses while maintaining the simplicity of the welding process. The enlarged section acts as a stress-relief feature that distributes loads more evenly across the junction.
2Ease of manufacture
If conventional welding is used without controlled fillet radii, then manufacturing is straightforward, but stress concentrations lead to structural integrity issues
Solution Approach 1:
The enlarged section with controlled fillet radius is formed as part of the strut fabrication process before the welding operation. This preliminary action ensures that the stress-relief geometry is already in place when welding occurs, allowing the weld to be made on a pre-prepared surface that promotes better stress distribution. The result is improved structural reliability without requiring complex post-weld stress relief operations.
Solution Approach 2:
By incorporating a large radius of curvature at the strut end (enlarged section), the design eliminates sharp corners that would otherwise create stress concentrations. This curved geometry is formed during strut fabrication and is maintained through the welding process, thereby improving the reliability of the strut-duct wall junction without complicating the manufacturing process.
3Strength
If the strut end is made with an enlarged section and controlled fillet radius, then stress concentrations are reduced, but the strut fabrication process becomes more complex
Solution Approach 1:
The enlarged section with controlled fillet radius is formed as an integral part of the strut body during the same fabrication process that creates the rest of the strut. This merging of operations allows the stress-relief geometry to be created without requiring separate manufacturing steps, thereby improving strength at the junction without significantly increasing overall device complexity or manufacturing time.
Solution Approach 2:
The strut fabrication process incorporates parameter changes to create the enlarged section with a specific radius of curvature. By adjusting forming parameters during strut fabrication (such as punch diameter, forming pressure, or rolling conditions), the desired geometry is achieved as part of the standard manufacturing process, avoiding the need for additional complex operations while improving structural strength.
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 design reduces stress concentrations at the strut-duct wall junctions, enhancing the structural integrity and durability of the vane ring by distributing loads more evenly and preventing sharp corner formation.
Implementation Method 1
a welded or brazed joint extends between the corresponding back surface and the enlarged section
Implementation Method 2
a welded or brazed joint extends between the corresponding back surface and the enlarged section
Data Source
AI summary
A strut configuration of a static vane ring used in a gas turbine engine having an enlarged end section at least at one of the opposed ends thereof to be welded or brazed to either an outer or inner duct wall of the vane ring. The enlarged end section provides a inner corner curve with a predetermined fillet radius between the strut and the duct wall.