U.S. patent application number 14/694435 was filed with the patent office on 2015-11-12 for blade element cross-ties.
This patent application is currently assigned to United Technologies Corporation. The applicant listed for this patent is Alex J. Simpson, Daniel A. SNYDER, Lane Thornton. Invention is credited to Alex J. Simpson, Daniel A. SNYDER, Lane Thornton.
Application Number | 20150322797 14/694435 |
Document ID | / |
Family ID | 53051744 |
Filed Date | 2015-11-12 |
United States Patent
Application |
20150322797 |
Kind Code |
A1 |
SNYDER; Daniel A. ; et
al. |
November 12, 2015 |
BLADE ELEMENT CROSS-TIES
Abstract
A blade element and methods of manufacturing blade elements are
provided for blade elements of a gas turbine engine. In one
embodiment, a blade element includes a first inner surface of the
blade element, wherein the first inner surface is associated with a
first outer blade surface of the blade element, and a second inner
surface of the blade element, wherein the second inner surface is
associated with a second outer blade surface of the blade element
and wherein the second inner surface is opposite from the first
inner surface. The blade element may also include a cross-tie
configured to connect the first inner surface to the second inner
surface, wherein the cross-tie is positioned along a trailing edge
of the blade element and the cross-tie is configured to reduce
vibration mode effects of the blade element.
Inventors: |
SNYDER; Daniel A.;
(Manchester, CT) ; Thornton; Lane; (Meriden,
CT) ; Simpson; Alex J.; (Tolland, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SNYDER; Daniel A.
Thornton; Lane
Simpson; Alex J. |
Manchester
Meriden
Tolland |
CT
CT
CT |
US
US
US |
|
|
Assignee: |
United Technologies
Corporation
Hartford
CT
|
Family ID: |
53051744 |
Appl. No.: |
14/694435 |
Filed: |
April 23, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61991328 |
May 9, 2014 |
|
|
|
Current U.S.
Class: |
416/229R ;
29/889.7 |
Current CPC
Class: |
F05D 2260/96 20130101;
F01D 5/16 20130101; F05D 2250/27 20130101; F01D 5/187 20130101;
Y10T 29/49337 20150115 |
International
Class: |
F01D 5/16 20060101
F01D005/16 |
Claims
1. A blade element for a gas turbine engine, the blade element
comprising: a first inner surface of the blade element, wherein the
first inner surface is associated with a first outer blade surface
of the blade element; a second inner surface of the blade element,
wherein the second inner surface is associated with a second outer
blade surface of the blade element and wherein the second inner
surface is opposite from the first inner surface; and a cross-tie
configured to connect the first inner surface to the second inner
surface, wherein the cross-tie is positioned along a trailing edge
of the blade element and the cross-tie is configured to reduce
vibration mode effects of the blade element.
2. The blade element of claim 1, wherein the cross-tie includes a
first portion blended to the first inner surface, a second portion
blended to the second inner surface, and a non-circular
cross-section between the first and second portions.
3. The blade element of claim 2, wherein the non-circular
cross-section is reduced in size relative to the first and second
portions of the cross-tie.
4. The blade element of claim 2, wherein the non-circular
cross-section is formed to include a non-circular blend between
first and second portions of the cross-tie blended to blade
surfaces.
5. The blade element of claim 1, wherein the cross-tie includes a
long axis oriented with the direction of centrifugal pull of the
blade element.
6. The blade element of claim 1, wherein the cross-tie increases
stability of the blade element by supporting the first and second
blade element surfaces in a hollow section of the blade
element.
7. The blade element of claim 1, wherein the second inner surface
is opposite from the first inner surface within at least one of
cooling passage and hollow portion of the blade element.
8. The blade element of claim 1, wherein vibration mode effects
include at least one of blade surface stress, blade surface strain,
vibratory stress, vibratory strain, and blade deformation.
9. The blade element of claim 1, wherein blade element includes a
plurality of cross-ties along the trailing edge of the blade
element.
10. The blade element of claim 9, wherein cross-ties of the blade
element are positioned between 20-90% of a span length of the blade
element.
11. A method for fabricating a blade element of a gas turbine
engine, the method comprising: forming a first blade surface of the
blade element, wherein the first blade surface includes a first
inner surface; forming a second blade surface of the blade element,
wherein the second blade surface includes a second inner surface
and wherein the second inner surface is opposite from the first
inner surface; and forming a cross-tie configured to connect the
first inner surface to the second inner surface along a trailing
edge of the blade element, wherein the cross-tie is positioned and
configured to reduce vibration mode effects of the blade
element.
12. The method of claim 11, wherein the cross-tie includes a first
portion blended to the first inner surface, a second portion
blended to the second inner surface, and a non-circular
cross-section between the first and second portions.
13. The method of claim 12, wherein the non-circular cross-section
is reduced in size relative to the first and second portions of the
cross-tie.
14. The method of claim 12, wherein the non-circular cross-section
is formed to include a non-circular blend between first and second
portions of the cross-tie blended to blade surfaces.
15. The method of claim 11, wherein the cross-tie includes a long
axis oriented with the direction of centrifugal pull of the blade
element.
16. The method of claim 11, wherein the cross-tie increases
stability of the blade element by supporting the first and second
blade element surfaces in at least one of a cooling passage and
hollow portion of the blade element.
17. The method of claim 11, wherein forming cross-ties includes
forming a plurality of cross-ties along the trailing edge of the
blade element.
18. The method of claim 17, wherein cross-ties of the blade element
are positioned between 20-90% of a span length of the blade
element.
19. The method of claim 11, further comprising determining one or
more cross-tie locations for the blade element.
20. The method of claim 19, wherein determining one or more
cross-tie locations for the blade element includes modeling a blade
element for one or more of vibratory frequency, vibratory mode
shape and vibratory stress.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 61/991,328 filed on May 9, 2014 and titled Blade
Element Cross-Ties, the disclosure of which is hereby incorporated
by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to components for a
gas turbine engine, and more particularly to blade elements
including cross-ties.
BACKGROUND
[0003] A gas turbine engine typically includes one or more blades
in each of the compressor and turbine sections of the engine. These
components are exposed to high-speed air/gas flow during operation.
In addition, gas turbine engine components are exposed to high
temperatures. As such, airfoils are typically provided with cooling
channels. Airfoil structures experience high levels of stress
during operation which may limit component operation life. There
exists a desire to extend the operational life of components.
[0004] Manufacturing of airfoil components can include using
ceramic cores to form passages in airfoils. Conventional methods
include the use of stiffening rods to supporting cast elements.
These rods are removed with cast elements during manufacture of the
component. Accordingly, there rods do not provide structural
support during operation.
[0005] While there have been approaches to fabricating components,
there is a need in the art to extend component life and improve
integrity.
BRIEF SUMMARY OF THE EMBODIMENTS
[0006] Disclosed and claimed herein are blade elements and methods
for making blade elements including cross-ties. In one embodiment,
a blade element for a gas turbine engine includes a first inner
surface of the blade element, wherein the first inner surface is
associated with a first outer blade surface of the blade element,
and a second inner surface of the blade element, wherein the second
inner surface is associated with a second outer blade surface of
the blade element and wherein the second inner surface is opposite
from the first inner surface. The blade element also includes a
cross-tie configured to connect the first inner surface to the
second inner surface, wherein the cross-tie is positioned along a
trailing edge of the blade element and the cross-tie is configured
to reduce vibration mode effects of the blade element.
[0007] According to another embodiment, a method for manufacturing
a blade element of a gas turbine engine includes forming a first
blade surface of the blade element, wherein the first blade surface
includes a first inner surface, and forming a second blade surface
of the blade element, wherein the second blade surface includes a
second inner surface and wherein the second inner surface is
opposite from the first inner surface. The method also includes
forming a cross-tie configured to connect the first inner surface
to the second inner surface along a trailing edge of the blade
element, wherein the cross-tie is positioned and configured to
reduce vibration mode effects of the blade element.
[0008] Other aspects, features, and techniques will be apparent to
one skilled in the relevant art in view of the following detailed
description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The features, objects, and advantages of the present
disclosure will become more apparent from the detailed description
set forth below when taken in conjunction with the drawings in
which like reference characters identify correspondingly throughout
and wherein:
[0010] FIGS. 1A-1C depict graphical representations of a blade
element according to one or more embodiments;
[0011] FIG. 2A depicts a graphical representation of a blade
element cross-tie according to one or more embodiments;
[0012] FIG. 2B depicts a cross-sectional view of the cross-tie of
FIG. 2A according to one or more embodiments;
[0013] FIG. 3 depicts a graphical representation of a blade element
cast according to one or more embodiments; and
[0014] FIG. 4 depicts a process for manufacturing a blade element
according to one or more embodiments.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
Overview and Terminology
[0015] One aspect of the disclosure relates to blade elements for a
gas turbine engine. According to one embodiment, a blade element,
such as fan blades, turbine blades and vanes, may be provided
including one or more cross-ties. As used herein, a cross-tie is a
structural element configured to provide rigidity to an interior
passage or hollow section of a blade element. According to one or
more embodiments, each cross-tie may have a curved profile with
surface blended to inner walls of a blade element. According to
another embodiment cross-ties may include a non-circular cross
section. Cross-ties may be placed and configured to provide support
and rigidity to unsupported areas of a blade element. Cross-ties
may additionally allow for internal connections within a blade
element without restricting airflow or changing heat transfer of
the blade element.
[0016] Another aspect of the disclosure is directed to
manufacturing blade elements to include one or more cross-ties.
According to one embodiment, a cast having positives and negatives
may be formed for manufacturing a blade element having one or more
cross-ties.
[0017] As used herein, the terms "a" or "an" shall mean one or more
than one. The term "plurality" shall mean two or more than two. The
term "another" is defined as a second or more. The terms
"including" and/or "having" are open ended (e.g., comprising). The
term "or" as used herein is to be interpreted as inclusive or
meaning any one or any combination. Therefore, "A, B or C" means
"any of the following: A; B; C; A and B; A and C; B and C; A, B and
C". An exception to this definition will occur only when a
combination of elements, functions, steps or acts are in some way
inherently mutually exclusive.
[0018] Reference throughout this document to "one embodiment,"
"certain embodiments," "an embodiment," or similar term means that
a particular feature, structure, or characteristic described in
connection with the embodiment is included in at least one
embodiment. Thus, the appearances of such phrases in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner on one or more embodiments without limitation.
[0019] Referring now to the figures, FIGS. 1A-1C depict graphical
representations of a blade element according to one or more
embodiments. Referring first to FIG. 1A, blade element 100 is shown
including leading edge 105, blade surface 106 (e.g., a first blade
surface) and trailing edge 110. Blade element 100 may be one of a
turbine blade, fan blade, vane, and gas turbine engine component.
FIG. 1A depicts blade element 100 including base structure 120.
[0020] According to one embodiment, blade element 100 may include
one or more cross-ties configured to connect a first blade surface,
such as an inner surface of blade surface 106, to a second inner
blade surface. By way of example, cross-ties may connect inner
surfaces of the blade element. Cross-ties may be positioned near
and/or along trailing edge 110 of blade element 100, wherein the
cross-tie is positioned and configured to reduce vibration mode
effects of the blade element 100. As discussed herein, vibration
mode effects can relate to one or more of blade surface stress,
blade surface strain, vibratory stress, vibratory strain, and blade
deformation. Cross-ties may be configured to provide stiffening to
reduce one or more of the vibratory effects. It should be
appreciated that the frequency of vibratory stress may be driven up
or down. While stress should be generally reduced everywhere in
blade element 100, there are situations where the vibratory
frequency needs to be driven upward. Thus, cross-ties as discussed
herein may be configured to stress and/or strain associated with
the vibratory mode of a blade element.
[0021] In one embodiment, cross-ties of blade element 100 are
positioned between 20-90% of a span length, shown generally as area
115 in FIG. 1A, of blade element 100. The trailing edge portion of
the blade may relate to portions of the blade element 100 near
trailing edge 110. Blade element 100 may include a plurality of
cross-ties along the trailing edge 110 in area 115. Each cross-tie
may be formed integrally with an inner surface of blade element 100
within a particular area shown as section 116. Section or area 116
is shown in more detail with respect to FIGS. 2A-2B. In some
embodiments, cross-ties may be positioned in other portions of
blade element 100.
[0022] FIG. 1B depicts a top down representation of blade element
100. As shown in FIG. 1B, blade element 100 includes a first blade
surface of the blade element, blade surface 106 with corresponding
first inner surface 108, and a second blade surface, blade surface
107 with corresponding second inner surface 109. Blade surface 108
is opposite from blade surface 109, wherein the blade surfaces are
between leading edge 105 and trailing edge 110. In one embodiment,
blade surface 108 is opposite from blade surface 109 meaning the
surfaces are on opposing ends of an interior portion. It can be
appreciated that surfaces 108 and 109 may be parallel,
substantially parallel, or not parallel. It can also be appreciated
that surfaces 108 and 109 may not correspond to the surface shape
characteristics of surfaces 106 and 107. By way of example, while
surfaces 106 and 107 may be smooth, surfaces 108 and 109 may be
formed on one or more protrusions of other interior features of a
blade element. As further depicted in FIG. 1B, blade element 100
includes a representation of cross-tie 130.sub.1. Cross-tie
130.sub.1 is configured to connect blade surface 106 to blade
surface 107. Cross-tie 130.sub.1 is positioned near trailing edge
110 of blade element 100. Cross-tie 130.sub.1 may be configured to
reduce vibration mode of blade element 100 by providing increased
stiffness for walls of the blade element.
[0023] FIG. 1C depicts a cut-away representation of blade element
100. According to one embodiment, blade element 100 may include
cooling area 125 to provide cooling air/air flow for cooling blade
element 100. Cooling area 125 may be one or more hollow sections of
blade element 100. Cross-ties 130.sub.1-n are shown relative to
inner surface 109 and near trailing edge 110. In certain
embodiments, cross-ties 130.sub.1-n may be positioned to provide
structural integrity without restricting airflow.
[0024] FIG. 2A depicts a graphical representation of a blade
element cross-tie according to one or more embodiments. In FIG. 2A,
section 200 of a blade element (e.g., blade element 100) includes
cross-tie 205. Cross-tie 205 includes a first portion blended to an
inner wall of blade surface 206, a second portion blended to an
inner wall of blade surface 207, and a non-circular cross-section
210 between the first and second portions. As shown in FIG. 2A,
non-circular cross-section 210 is reduced in size relative to the
first and second portions of the cross-tie blended to blade
surfaces. Cross-tie 205 may be configured to provide a connection
between surfaces 206 and 207 and provide both in-plane (shear) and
out-of-plane (compressive/tensile) support. By providing
stiffening, cross-tie 205 can reduce the extent to which surfaces
206 and 207 participate in the vibration mode of the blade
element.
[0025] FIG. 2B depicts a cross-sectional view of the cross-tie of
FIG. 2A according to one or more embodiments. Blade element section
250 is a cross sectional view along reference line A-A of FIG. 2A,
which is associated with the central axis of the cross-tie 205. As
shown in FIG. 2A, cross-tie 205 is formed to include a non-circular
blend between first and second portions of the cross-tie blended to
blade surfaces. Non-circular curved/bending is shown by arcs 255,
260, 265 and 270. Cross-tie 205 includes a long axis oriented with
the direction of centrifugal pull of a blade element (e.g., blade
element 105). According to one embodiment, cross-tie 205 increases
stability of the blade element by supporting the first and second
blade element surfaces in a hollow section of the blade element.
Cross-tie 205 may be configured to provide in-plane and
out-of-plane support for the blade element. In-plane support
provided by the blade element may relate support along an axis of
cross-tie 205, while out-of-plane support may relate to support for
vibratory and steady state stress of the blade element in
general.
[0026] FIG. 3 depicts a graphical representation of a blade element
cast according to one or more embodiments. According to one
embodiment, blade elements (e.g., blade element 100) may be cast to
include one or more cross-ties. Cast 300 is a simplified
representation of a cast element including negatives and positives
that may be employed to fabricate a blade element as described
herein. As shown in FIG. 3, cast 300 includes a plurality of
negatives, shown as 305.sub.1-n, to allow for cross-ties to be
formed. Cast 300 also includes a plurality of positives, shown as
310.sub.1-n, to allow for cooling passages to be formed.
[0027] FIG. 4 depicts a process for manufacturing a blade element
(e.g., blade element 100) according to one or more embodiments.
Process 400 may be initiated at block 405 with determining one or
more cross-tie locations for a blade element. By way of example,
modeling of a blade element may indicate one or more locations
where additional stiffness or an internal connection is required.
In certain embodiments, determining one or more cross-tie locations
for the blade element includes modeling a blade element for one or
more of vibratory frequency, vibratory mode shape and vibratory
stress.
[0028] At block 410, a cast (e.g., cast 300) for the blade element
may be generated. According to one embodiment, a cast may be formed
at block 410 to include one or more negatives and positives, to
form cross-ties and cooling paths.
[0029] Process 400 may continue to block 415 to fabricate a blade
element based on the cast generated at block 410 to include one or
more cross-ties. In one embodiment, fabricating a blade element of
a gas turbine engine at block 415 includes forming a first blade
surface of the blade element, and forming a second blade surface of
the blade element, wherein the second blade surface is opposite
from the first blade surface. Fabricating a blade element of a gas
turbine engine at block 415 may also include forming one or more
cross-ties configured to connect the inner surface of a first blade
surface to the inner surface of a second blade surface on a
trailing edge of the blade element. Forming cross-ties at block 415
can include forming a plurality of cross-ties along the trailing
edge of the blade element.
[0030] While this disclosure has been particularly shown and
described with references to exemplary embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
scope of the claimed embodiments.
* * * * *