Turbine Blade Shroud Segmentation for 3D Lamination Assembly
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Solution Overview
Problem
The manufacturing of turbine blades by a three-dimensional lamination method requires extensive support materials and time due to the need for complex shroud structures, leading to increased labor and post-treatment requirements.
Innovation Solution
A method involving separate formation of blade body and shroud divided bodies using three-dimensional lamination, followed by joining using laser powder overlay welding, allowing for reduced support material usage and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the blade body and shroud are formed together by a three-dimensional lamination method, then the structural integrity is improved, but the amount of support material required increases significantly
Solution Approach 1:
The turbine blade is divided into separate components: the blade body and the shroud are formed as independent parts through three-dimensional lamination. This segmentation allows each component to be manufactured separately with minimal support material, eliminating the need for extensive support structures required when forming the complete assembly in one piece.
2Strength
If the blade body and shroud are formed together by a three-dimensional lamination method, then the structural integrity is improved, but the manufacturing time and labor increase
Solution Approach 1:
By segmenting the manufacturing process into separate formation of blade body and shroud components, each part can be produced independently and more efficiently. The reduced complexity of each individual component decreases lamination time and simplifies post-treatment operations, thereby reducing overall manufacturing time and labor requirements.
Solution Approach 2:
The blade body and shroud are preliminarily formed as separate completed components before final assembly. This preliminary action allows each component to be optimized and prepared independently, reducing the time and labor required during the final assembly process while maintaining structural integrity.
3Strength
If the blade body and shroud are formed together by a three-dimensional lamination method, then the structural integrity is improved, but the post-treatment complexity increases
Solution Approach 1:
Segmenting the blade into separately formed components reduces post-treatment complexity because each component has a simpler geometry that requires less support material. This simplifies the dissolution or removal of support materials and reduces the complexity of post-lamination processing steps.
4Area of stationary object
If separate lamination directions are used for blade body and shroud, then the lamination area is reduced, but the joining complexity increases
Solution Approach 1:
The segmentation of the blade into separate components with independent lamination directions allows for optimized manufacturing of each part. The joining complexity is managed through precise positioning features and standardized connection interfaces that are incorporated into the design of the segmented components.
Solution Approach 2:
Positioning features and connection interfaces act as intermediaries between the separately laminated blade body and shroud. These intermediary elements facilitate accurate alignment and secure joining of the components, managing the complexity of assembly while allowing independent optimization of each component's lamination process.
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
This approach significantly reduces the time and labor required for lamination and post-treatment, enhancing manufacturing efficiency and maintaining the quality of turbine blades.
Implementation Method 1
joining using laser powder overlay welding
Implementation Method 2
joining using laser powder overlay welding
Data Source
AI summary
A method of manufacturing a turbine blade includes forming a blade body divided body constituting a blade body of the turbine blade by a three-dimensional lamination method; individually forming a plurality of shroud divided bodies constituting a shroud of the turbine blade for each of the shroud divided bodies by a three-dimensional lamination method; joining the shroud divided bodies together; and joining the blade body divided body and the shroud divided bodies.