Turbomachine Vane Frame Weight Reduction via Localized Material Selection
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Solution Overview
Problem
High-bypass turbofan engine vane frames require a balance between structural support and weight reduction, with existing composite materials necessitating complex geometries and increased weight and costs.
Innovation Solution
A vane frame design where guide vanes are formed of different materials, with load-bearing vanes made of higher-strength materials and non-load-bearing vanes made of lighter, less costly composite materials, minimizing weight by distributing structural loads primarily through the higher-strength vanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used for outlet guide vanes to reduce weight, then weight is reduced, but complex attachment geometries and hardware are required which increases weight and manufacturing costs
Solution Approach 1:
The patent applies local quality by differentiating between load-bearing and non-load-bearing vanes. Load-bearing vanes (positions 1-8 and 25-32) are constructed from high-strength metallic materials to provide structural support, while non-load-bearing vanes (positions 9-24 and 33-48) are made from lighter composite materials for aerodynamic functions only. This localized material selection optimizes weight reduction in non-critical areas while maintaining structural integrity where needed, avoiding the need for complex attachment geometries throughout the entire vane frame.
2Weight of moving object
If composite materials are used for outlet guide vanes to reduce weight, then weight is reduced, but manufacturing and material costs increase
Solution Approach 1:
The patent implements local quality by restricting composite material usage to non-load-bearing vanes where weight reduction provides aerodynamic benefits without compromising structural support. Load-bearing vanes continue to use cost-effective metallic materials with proven manufacturing processes. This selective approach reduces overall weight while controlling manufacturing costs by avoiding expensive composite materials in applications where they provide minimal benefit.
3Strength
If uniform high-strength materials are used for all guide vanes to ensure structural support, then structural integrity is maintained, but weight increases
Solution Approach 1:
The patent applies local quality by strategically distributing high-strength metallic materials only to load-bearing vanes at specific positions (1-8 and 25-32) where structural support is critical for maintaining fan nacelle loads. Non-load-bearing vanes at other positions use lighter composite materials sufficient for their aerodynamic functions. This localized strength distribution maintains overall structural integrity while significantly reducing total weight compared to uniform high-strength material construction.
Solution Approach 2:
The patent segments the vane frame into distinct load-bearing and non-load-bearing sections, with load-bearing vanes providing structural support and non-load-bearing vanes providing aerodynamic functions. This segmentation allows each section to be optimized for its specific function, with metallic materials concentrated where structural strength is most needed and composite materials used where weight reduction is most beneficial.
Data Source
AI summary
A vane frame for a turbomachine and a method for minimizing the weight of a vane frame. The vane frame includes an inner shroud made up of a plurality of inner shroud segments, an outer shroud circumscribing the inner shroud and made up of a plurality of outer shroud segments, and guide vanes structurally interconnecting the inner and outer shrouds. The guide vanes include a plurality of first guide vanes between and connecting first pairs of the inner and outer shroud segments, and a plurality of second guide vanes between and connecting second pairs of the inner and outer shroud segments. The first and second guide vanes are formed of different first and second materials, respectively, with the first material having lower strength, modulus, and/or density than the second material. The structural interconnection between the inner and outer shrouds is dominated by the second guide vanes.