Turbine Stator Blade Tip Geometry for Friction Reduction
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Solution Overview
Problem
Gas turbine engine stator blades experience excessive friction and wear due to contact with rotors, leading to heat generation and reduced seal integrity, which existing blade seal configurations fail to adequately address.
Innovation Solution
A stator segment design featuring a shroud band with radially inward protruding blades, each defined by a first and second thickness section with a faired transition, allowing for even casting and controlled tip wear, and a method involving casting and trimming to achieve optimal tip length and reduced variance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the tip of the stator blade is milled to be thinner, then friction and heat generation are reduced, but manufacturing complexity increases and structural strength may be compromised
Solution Approach 1:
The patent changes the geometric parameters of the blade tip by introducing a tapered section with gradually varying thickness. Instead of a sudden thinning, the blade tip transitions from the full thickness of the blade body to a reduced thickness through a controlled gradient, optimizing the balance between friction reduction and structural integrity
Solution Approach 2:
The patent applies curvature to the blade tip geometry by creating a rounded, faired transition zone instead of a sharp or flat reduction. This curved tapering profile reduces stress concentrations and improves aerodynamic flow while maintaining manufacturing feasibility through standard forming processes
2Object-generated harmful factors
If the blade tip is made thinner to reduce contact surface area, then friction is reduced, but the blade becomes more susceptible to wear and structural failure
Solution Approach 1:
The patent implements a gradual parameter change in the blade tip thickness, transitioning from the full blade thickness to a reduced tip thickness through a tapered section. This gradual transition maintains structural integrity by avoiding abrupt geometric changes that would create stress concentrations and vulnerability points
Solution Approach 2:
The faired, rounded transition zone at the blade tip acts as a cushioning feature that distributes contact stresses more evenly during operation. This pre-designed stress distribution mechanism protects the thinner tip section from localized wear and structural failure
3Reliability
If a blade seal configuration is used to create seal integrity, then seal performance is improved, but friction and heat generation increase
Solution Approach 1:
The patent applies local quality modification by changing the geometry specifically at the blade tip region while maintaining the full thickness and geometry of the blade body. The tapered section creates a localized thinning that reduces contact area and friction only where necessary, preserving seal integrity through controlled local modification rather than global changes
Solution Approach 2:
The blade is segmented into distinct geometric zones: a full-thickness blade body for structural strength and seal contact, and a reduced-thickness tapered tip for friction reduction. This segmentation allows each zone to optimize its function independently
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 friction and heat generation while maintaining seal integrity by allowing controlled wear and minimizing thickness variance, enhancing the performance and longevity of the stator segment.
Implementation Method 1
a faired section (240) transitioning from the first section to the second section
Implementation Method 2
A blade seal uses contact between stator blades and rotors to create the seal. Use of a blade seal introduces friction between the stator blades and the rotor, thereby generating heat and wearing the stator blades
Implementation Method 3
introduces friction between the stator blades and the rotor, thereby generating heat and wearing the stator blades
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A gas turbine engine stator segment (200) has a shroud band (210) and a plurality of blade sections (260). Each of the blade sections (260) has a first section (420) with a first thickness (484), second section (430) with a second thickness (432) and a fairing section (440) transitioning between the first section (420) and second section (430). The second section thickness (432) is less than the first section thickness (484).