Turbine Engine Casing Support Panel Machining

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for manufacturing support panels for turbine engine casings with abradable coatings are complex, requiring precise tooling, high tolerances, and autoclave processing, which leads to defects and increased production costs due to the need for intumescent materials and rigidification of the support panel.

Innovation Solution

A method that involves machining the outer surface of the honeycomb block to match the inner casing profile before assembly with a rigid panel, eliminating the need for intumescent materials and reducing tooling complexity, using conventional cooking means and lower tolerances to simplify the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the support panel is rigidified by cooking impregnated composite material, then the panel gains structural strength, but the machining precision deteriorates due to difficulty in machining rigidified material

Engineering Contradiction:

Improvestructural strength of support panelVSAvoidmachining precision of outer surface

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The manufacturing process is segmented into two distinct phases: first, the honeycomb block is machined to the required precision while still in its raw, unrigidified state; second, the rigid panel is cooked and then assembled to the machined block. This segmentation allows machining operations to be performed on the more workable raw material before rigidification, thereby maintaining high machining precision while still achieving the required structural strength through subsequent cooking of the rigid panel.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If intumescent material is interleaved between the block and rigid panel, then the assembly expands to fill gaps, but the manufacturing complexity increases due to additional materials and processing steps

Engineering Contradiction:

Improvegap filling and expansion stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The intumescent material layer is completely removed from the manufacturing process. Instead of using intumescent material to fill gaps between the block and rigid panel, the invention relies on precise machining of the block's outer surface to match the inner casing profile, eliminating the need for gap-filling expansion materials and thereby reducing manufacturing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If high tolerances are used in machining the support panel, then the fitment precision to the casing is improved, but the production cost increases due to stricter quality control and rework

Engineering Contradiction:

Improvefitment precision to casingVSAvoidproduction cost and complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The outer surface of the block is machined to the required precision in advance, before the rigid panel is cooked and assembled. This preliminary machining action is performed on the raw honeycomb block which is more easily machined than the rigidified composite panel, thereby achieving high fitment precision to the casing while reducing production costs by avoiding the need for expensive precision machining of the rigidified panel.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If autoclave processing is used to cook the rigid panel, then the composite material is properly cured, but the production time increases and equipment requirements are more stringent

Engineering Contradiction:

Improvecuring quality of composite materialVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The curing process is segmented so that only the rigid panel requires autoclave processing, while the honeycomb block can be processed using conventional, faster cooking means. This segmentation reduces overall production time and lessens equipment requirements compared to autoclaving the entire assembly, while still ensuring proper curing of the composite rigid panel.

Inventive Principle:

Principle #1Segmentation

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 simplifies the machining and assembly of support panels, reduces defects, and lowers production costs by avoiding the need for complex tooling and autoclave processing, while ensuring accurate fitment and adherence of the abradable material cartridge.

Implementation Method 1

the blades, which can, when functioning, rub against the abradable material and wear it by friction

Methodology Applied

Scientific EffectFriction wear: Wear

Implementation Method 2

a resin injection, said resin being then polymerised directly on a block of honeycomb material

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS11002145B2Method for manufacturing a turbine engine casing with abradable coating

Publication Date: 2021.05.11 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A method for manufacturing a panel for supporting at least one cartridge of abradable material for a turbine engine casing, the panel including at least one block of material and a rigid panel covering the at least one block of material, except for a free outer surface configured to be fixed to an inner surface of the casing, including: a step of machining the outer surface of the block of material according to a three-dimensional profile configured to match that of the inner surface of the casing, and a step of fixing the machined block to the rigid panel.