Additive Manufacturing Swirler Stacks with Frangible Supports
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Solution Overview
Problem
Conventional methods for manufacturing air swirlers, such as those used in fuel injectors and nozzles, are costly and time-consuming due to intricate geometries and limitations in traditional machining and additive manufacturing, particularly in producing large quantities with current build plate sizes.
Innovation Solution
The method involves additive manufacturing of a vertical stack of swirlers with an external ring and central support rod, using frangible features to support and separate individual swirlers, allowing for efficient production and machining to achieve complex geometries while minimizing post-build cleanup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining is used to manufacture swirlers with intricate geometries, then manufacturing precision can be achieved, but production time and cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing technology. The swirler components with complex aerodynamic geometries are built layer-by-layer using additive manufacturing, eliminating the need for conventional CNC machining operations. This substitution maintains manufacturing precision while dramatically improving production efficiency and reducing manufacturing time.
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive machining to additive construction. By using additive manufacturing parameters (layer height, infill density, build orientation) instead of machining parameters (cutting speed, feed rate, tool paths), the process achieves both high precision for complex geometries and high productivity through parallel building of multiple components.
2Adaptability or versatility
If traditional additive manufacturing is used to produce swirlers, then complex geometries can be accommodated, but production speed and cost remain high due to limited build plate size
Solution Approach 1:
The patent merges multiple individual swirler components into a single integrated build unit. By designing the additive manufacturing process to produce stacks or arrays of swirlers simultaneously on one build plate, the system maximizes the utilization of available build volume. This combining approach maintains the ability to create complex geometries while dramatically increasing production rate by manufacturing multiple parts in parallel.
Solution Approach 2:
The patent transitions from manufacturing single swirlers in isolation to producing three-dimensional stacks of swirlers vertically arranged on the build plate. This dimensional change allows efficient use of build plate space by building upward rather than only outward, enabling high-volume production while maintaining geometric complexity through the additive process.
3Adaptability or versatility
If additive manufacturing is used to manufacture swirlers, then design flexibility for complex geometries is achieved, but support structure cleanup time and complexity increase
Solution Approach 1:
The patent segments the support structure design into standardized, easily removable features. By incorporating frangible support structures with defined break points and separation features, the complex support removal process is simplified into discrete, quick operations. This segmentation maintains design flexibility for the swirler geometries while reducing post-build cleanup time through systematic separation of supports from finished parts.
Solution Approach 2:
The patent introduces frangible support structures as intermediary elements that facilitate easy separation. These temporary support features are designed to be easily broken or removed after manufacturing, acting as mediators between the additive manufacturing process and the final clean part. This intermediary approach preserves design flexibility during building while minimizing cleanup effort afterward.
Data Source
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AI summary
A swirler (100) includes an inner body (102) defining a swirl axis (A). A plurality of swirl vanes (104) extend outward from the inner body. The swirl vanes define respective swirl slots (106) therebetween for imparting swirl on a fluid passing through the swirl slots. A method of making swirlers includes additively manufacturing a stack of swirlers.