U.S. patent application number 15/023854 was filed with the patent office on 2016-08-18 for method of generating support structure of tube components to become functional features.
This patent application is currently assigned to United Technologies Corporation. The applicant listed for this patent is UNITED TECHNOLOGIES CORPORATION. Invention is credited to Evan Butcher, Lexia Kironn, Joe Ott, Gary A. Schirtzinger, Wendell V. Twelves, Jr..
Application Number | 20160238324 15/023854 |
Document ID | / |
Family ID | 52689331 |
Filed Date | 2016-08-18 |
United States Patent
Application |
20160238324 |
Kind Code |
A1 |
Butcher; Evan ; et
al. |
August 18, 2016 |
METHOD OF GENERATING SUPPORT STRUCTURE OF TUBE COMPONENTS TO BECOME
FUNCTIONAL FEATURES
Abstract
A method includes building a tubular object by a layer-by-layer
additive manufacturing process. A structure integrally connected to
the tubular object for supporting a portion of the tubular object
is formed during building of the tubular object. The structure
provides vibration dampening, heat shielding, heat transfer,
stiffening, energy absorption, or mounting after the tubular object
is built.
Inventors: |
Butcher; Evan; (Manchester,
CT) ; Twelves, Jr.; Wendell V.; (Glastonbury, CT)
; Schirtzinger; Gary A.; (Glastonbury, CT) ; Ott;
Joe; (Enfield, CT) ; Kironn; Lexia; (Rocky
Hill, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED TECHNOLOGIES CORPORATION |
Hartford |
CT |
US |
|
|
Assignee: |
United Technologies
Corporation
Hartford
CT
|
Family ID: |
52689331 |
Appl. No.: |
15/023854 |
Filed: |
September 17, 2014 |
PCT Filed: |
September 17, 2014 |
PCT NO: |
PCT/US2014/055980 |
371 Date: |
March 22, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61881216 |
Sep 23, 2013 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 64/112 20170801;
F16L 59/08 20130101; B29C 64/153 20170801; F28F 2265/30 20130101;
F16L 9/02 20130101; B29C 64/10 20170801; B33Y 10/00 20141201; B29C
64/165 20170801; F28F 1/00 20130101; F28F 2225/04 20130101; F16L
55/02 20130101; F16L 3/00 20130101; F16L 9/19 20130101; F28F 1/124
20130101; F28F 1/40 20130101; F28F 2265/10 20130101; B29C 64/106
20170801; B28B 1/001 20130101; F28F 2255/00 20130101; B33Y 80/00
20141201; F16L 9/006 20130101; F16L 9/21 20130101; B29C 64/118
20170801; B29D 23/00 20130101; B29L 2023/22 20130101; B29C 64/124
20170801; B29C 64/40 20170801; F28F 1/12 20130101 |
International
Class: |
F28F 1/12 20060101
F28F001/12; B29D 23/00 20060101 B29D023/00; F16L 9/02 20060101
F16L009/02; B29C 67/00 20060101 B29C067/00 |
Claims
1. A method comprising: building a tubular object by a
layer-by-layer additive manufacturing process; forming, while
building the tubular object, a structure integrally connected to
the tubular object for supporting a portion of the tubular object
with the structure during building of the tubular object, and for
providing vibration dampening, heat shielding, heat transfer,
stiffening, energy absorption, or mounting after the tubular object
is built.
2. The method of claim 1, wherein a portion of the structure
comprises a heat-shield structure, mounting structure, honeycomb
structure, fin structure, matrix structure, lattice structure, rib
structure, filter structure, bushing structure, or slot.
3. The method of claim 1, wherein the tubular object includes at
least one channel therein extending for the length of the tubular
object, and the at least one channel is configured to allow
transport of a fluid through the tubular object.
4. The method of claim 3, wherein the structure is disposed within
the tubular object and the structure is configured to allow
transport of the fluid through the tubular object.
5. The method of claim 3, wherein the fluid comprises oil, fuel,
gas, or air.
6. The method of claim 1, wherein the tubular object comprises a
tube designed for use in a gas turbine engine.
7. An apparatus comprising: a tubular object, the tubular object
built by layer-by-layer additive manufacturing; and a structure
comprising a heat-shield structure, mounting structure, honeycomb
structure, fin structure, matrix structure, lattice structure, rib
structure, filter structure, bushing structure, or slot, the
structure integrally formed to the tubular object and positioned to
act as a support structure during building of the tubular object by
layer-by-layer additive manufacturing.
8. The apparatus of claim 7, wherein the structure is configured to
perform at least one of vibration dampening, heat shielding, heat
transfer, stiffening, energy absorption, or mounting.
9. The apparatus of claim 7, wherein the tubular object includes at
least one channel therein extending for the length of the tubular
object, and the at least one channel is configured to allow
transport of a fluid through the tubular object.
10. The apparatus of claim 9, wherein the structure is disposed
within the tubular object and the structure is configured to allow
transport of the fluid through the tubular object.
11. The apparatus of claim 9, wherein the fluid comprises oil,
fuel, gas, or air.
12. The apparatus of claim 7, wherein the tubular object comprises
a tube designed for use in a gas turbine engine.
13. A method comprising: designing a component having a tubular
body and a structure that performs at least one of vibration
dampening, heat shielding, heat transfer, stiffening, energy
absorption, or mounting, wherein the structure is positioned with
respect to the tubular body so that the structure will act as a
support to the component during layer-by-layer additive
manufacturing of the component; creating digital files defining the
component on a layer-by-layer basis; and producing the component by
layer-by-layer additive manufacturing using the digital files.
14. The method of claim 13, wherein a portion of the structure
comprises a heat-shield structure, mounting structure, honeycomb
structure, fin structure, matrix structure, lattice structure, rib
structure, filter structure, bushing structure, or slot.
15. The method of claim 13, wherein the tubular object includes at
least one channel therein extending for the length of the tubular
object, and the at least one channel is configured to allow
transport of a fluid through the tubular object.
16. The method of claim 15, wherein the structure is disposed
within the tubular object and the structure is configured to allow
transport of the fluid through the tubular object.
17. The method of claim 15, wherein the fluid comprises oil, fuel,
gas, or air.
18. The method of claim 13, wherein the tubular object comprises a
tube designed for use in a gas turbine engine.
Description
BACKGROUND
[0001] This invention relates generally to the field of additive
manufacturing. In particular, the present disclosure relates to
support structures used during additive manufacturing.
[0002] Additive manufacturing is an established but growing
technology. In its broadest definition, additive manufacturing is
any layerwise construction of articles from thin layers of feed
material. Additive manufacturing may involve applying liquid,
layer, or particle material to a workstage, then sintering, curing,
melting, and/or cutting to create a layer. The process is repeated
up to several thousand times to construct the desired finished
component or article.
SUMMARY
[0003] A method includes building a tubular object by a
layer-by-layer additive manufacturing process. A structure
integrally connected to the tubular object for supporting a portion
of the tubular object is formed during building of the tubular
object. The structure provides vibration dampening, heat shielding,
heat transfer, stiffening, energy absorption, or mounting after the
tubular object is built.
[0004] An apparatus includes a tubular object built by
layer-by-layer additive manufacturing. A structure including a
heat-shield structure, mounting structure, honeycomb structure, fin
structure, matrix structure, lattice structure, rib structure,
filter structure, bushing structure, or slot is integrally formed
to the tubular object. The structure is positioned to act as a
support structure during building of the tubular object by
layer-by-layer additive manufacturing.
[0005] A method includes designing a component having a tubular
body and a structure that performs at least one of vibration
dampening, heat shielding, heat transfer, stiffening, energy
absorption, or mounting. The structure is positioned with respect
to the tubular body so that the structure will act as a support to
the component during layer-by-layer additive manufacturing of the
component. Digital files are created that define the component on a
layer-by-layer basis. The component is then produced by
layer-by-layer additive manufacturing using the digital files.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A is a flow-diagram representing a prior art additive
manufacturing process.
[0007] FIG. 1B is a flow-diagram representing an additive
manufacturing process.
[0008] FIG. 2 is a simplified perspective view of a tubular object
with a vibration control structure.
[0009] FIG. 3 is a simplified perspective view of a tubular object
with mounting tabs.
[0010] FIG. 4 is a simplified sectional view of a tubular object
with mounting tabs.
[0011] FIG. 5 is a simplified perspective view of a tubular object
with heat-transferring fins.
[0012] FIG. 6 is a simplified perspective view of a tubular object
with a stand-off heat shield.
[0013] FIG. 7 is a simplified perspective view of a tubular object
with stiffening ribs.
[0014] FIG. 8 is a simplified sectional view of a tubular object
with ribs.
[0015] FIG. 9 is a simplified sectional view of a tubular object
with a filter.
[0016] FIG. 10 is a simplified sectional view of a tubular object
with a compliant matrix.
[0017] FIG. 11 is a simplified sectional view of a tubular object
with a honeycomb support structure.
[0018] FIG. 12 is a simplified sectional view of a tubular object
with spring elements.
DETAILED DESCRIPTION
[0019] FIG. 1A is a flow-diagram representing prior art additive
manufacturing process 10. Prior art additive manufacturing process
10 includes steps 12-20. Step 12 includes designing a tubular
object with a support structure. Step 14 includes beginning to
build the tubular object with the support structure. Step 16
includes supporting the tubular object with the support structure
during the building of the tubular object. Step 18 includes
completing building of the tubular object. Step 20 includes
removing the support structure from the tubular object.
[0020] If a designer wants to build a tubular object vertically
using an additive manufacturing process, the object will build
quite nicely. If the tubular object is a simple short, straight
tubular object, a vertical build orientation without support
structures will suffice because as the tubular object is built
layer-by-layer, the previous layers support the new layers being
deposited directly vertical to the previous layers. However, the
geometry and the build orientation are not always favorable to the
fabrication of a cross section of the tube in a vertical
orientation. As soon as the overhead features of the tubular object
exceed a build limit angle of approximately 45 degrees off
vertical, dendrites and stalactites can form on the tubular object
and ruin the build. For example, for selective laser sintering,
when the laser penetrates the melt pool of the current layer and
there is not a previously formed subjacent layer of material
supporting the current layer, the laser penetrates the current
layer without a backstop. The laser penetrates the current layer
and causes material of the current layer to protrude downward from
the current layer causing the formation of stalactites and
dendrites.
[0021] Examples of tubular objects requiring over-head features
exceeding the build limit angle off-vertical build direction can
include tubes following a serpentine path, tubes having to fit in
an envelope, tubes wrapping around a bearing housing, or tubes
wrapping around other tubes.
[0022] In these instances, support structures are needed to support
the tubular object during the building to prevent portions of the
tube from drooping or sagging, and to prevent the formation of
stalactites and dendrites. Support structures used during the
additive manufacturing build of the tube can be formed either
inside or outside of the tube. The support structures help support
the weight of portions of the tube as the tube is being built.
[0023] FIG. 1B is a flow-diagram representing additive
manufacturing process 22. Additive manufacturing process 22
includes steps 24-34. Step 24 includes designing a tubular object
with an integral support structure. Step 26 includes incorporating
a post-build functional use for the integral support structure.
Step 28 includes beginning to build the tubular object with the
integral support structure. Step 30 includes supporting the tubular
object with the integral support structure during the building of
the tubular object. Step 32 includes completing building of the
tubular object. Step 34 includes performing the post-build
functional use of the integral support structure.
[0024] Typically, a support structure used during prior art
additive manufacturing process 10 becomes waste parent material
that is inherent in an additive manufacturing process after an
object is built. Additive manufacturing process 22 allows for the
integral support structure to be retained with the tubular
structure both during the build, and after the build of the tubular
object to perform a post-build functional use. Functional uses that
are added to tubes to handle vibration frequencies, to control the
heat transfer of fluids within tubes, or to mount tubes are often
expensive, add weight, and increase the part count of an overall
assembly. Additive manufacturing process 22 can design these
functional uses as part of the integral support structure to become
a functional piece of the tubular object. Functional uses of the
integral support structure may include vibration dampening, heat
shielding, heat transfer, stiffening, energy absorption, or
mounting. The integral support structure may include a heat-shield
structure, mounting structure, honeycomb structure, fin structure,
matrix structure, lattice structure, rib structure, filter
structure, bushing structure, or slot.
[0025] The structural connection between a tubular object and a
support structure is much stronger with additive manufacturing
process 22 as compared to traditional non-additive manufacturing
processes of attachment for structural supports. Traditional
non-additive manufacturing processes can include welding. With
welding, because the two pieces of material are different, the
connection between the two is not as strong or reliable as if the
two pieces were integrally formed as one part as with additive
manufacturing process 22. Traditional non-additive manufacturing
processes can also include casting, extruding, and machining.
[0026] With additive manufacturing process 22, complex geometries
are achievable which may not be economically feasible with
traditional non-additive manufacturing processes. Additive
manufacturing process 22 eliminates the need to employ commonly
expensive traditional non-additive manufacturing processes of
attaching structural support members after the initial build of the
tubular object. Additionally, employing traditional non-additive
manufacturing processes to create complex geometries can become
very expensive. Three dimensional structural matrices, made
possible by additive manufacturing, enable fewer raw materials to
be used therefore decreasing the weight, while still maintaining a
high degree of structural integrity within the part.
[0027] FIG. 2 is a simplified perspective view of tubular object 36
with vibration control structure 42. Tubular object 36 includes
tube 38 and truss structures 40 that are integrally formed to tube
38. Truss structures 40 integrally connect tube 38 to vibration
control structure 42. Vibration control structure 42 surrounds tube
38. Vibration control structure 42 includes voids 44 interspersed
along the length of vibration control structure 42.
[0028] Vibration control structure 42 raises the natural frequency
of tube 38 by increasing the moment of inertia of tube 38. The
size, shape, and location of voids 44 can be designed specifically
to the desired vibration response of vibration control structure
42. Integrally forming vibration control structure 42 to tube 38
during additive manufacturing process 22 provides a higher degree
of customization and design freedom than traditional non-additive
manufacturing processes allow.
[0029] During the building of tubular object 36, truss structures
40 and vibration control structure 42 provide structural support
for tube object 38 by helping to brace tube 38. As tubular object
36 is formed layer-by-layer, truss structures 40 and vibration
control structure 42 help to keep tubular object 36 within
geometric build constraints of additive manufacturing process
22.
[0030] FIG. 3 is a simplified perspective view of tubular object 46
with mounting tabs 54. Tubular object 46 includes tube 48 which is
integrally connected to connections 50. Honeycomb support structure
52 is positioned adjacent to tube 48 and to connections 50. Base
plate 54 is connected to tube 48 by connections 50. Base plate 54
is integrally formed to connections 50 and connections 50 are
integrally formed to tube 48. Honeycomb matrix structure 52 is
integrally formed to tube 48 and to connections 50.
[0031] The integral relationship between tube 48, connections 50,
and base plate 54 prevents the need to attach non-integral support
structures to tube 48 after tube 48 is built. Non-integral support
structures attached to tube 48 after tube 48 is built can create
weak connection points where the non-integral support structure is
attached to tube 48. Integrally connecting base plate 54 and tube
48 provides connections 50 that is able to withstand a greater
amount of stress and strain than a non-integral support structure
attached to tube 48 would be able to withstand. Non-integral
connection means can fail when a tubular object is placed into an
in-use environment within a gas turbine engine. An example of a
non-integral connection means includes welding.
[0032] FIG. 4 is a simplified sectional view of tubular object 56
with mounting tabs 64. Tubular object 56 includes tube 58 which is
connected to connections 60. Honeycomb support structure 62 is
positioned adjacent to tube 58 and to connections 60. Mounting tabs
64 are integrally connected to tube 58 by connections 60. Mounting
tabs 64 are integrally formed to connections 60, and connections 60
are integrally formed to tube 58. Honeycomb support structure 62 is
integrally formed to tube 58 and to connections 60.
[0033] Honeycomb support structure 64 provides structural support
between tube 58 and mounting tabs 64. The porous nature of
honeycomb support structure 62 provides for a lighter weight
support feature for tube 60 as opposed to a completely solid
support structure.
[0034] FIG. 5 is a simplified perspective view of tubular object 66
with fins 70. Tubular object 66 includes fins 70. Fins 70 are
integrally connected to tube 68. Fins 70 perform a
heat-transferring function by transferring thermal energy away from
tube 68.
[0035] The size, shape, surface-area, and location of fins 70 can
be designed specifically to a desired thermal management
functionality of fins 70. Integrally forming fins 70 to tube 68
during additive manufacturing process 22 provides a higher degree
of customization and design freedom than traditional non-additive
manufacturing processes allow.
[0036] FIG. 6 is a simplified perspective view of tubular object 72
with a stand-off heat shield 78. Tubular object 72 includes tube 74
and truss structures 76 integrally formed to tube 74. Truss
structures 76 integrally connect tube 74 to stand-off heat shield
78. Stand-off heat shield 78 surrounds tube 74. Stand-off heat
shield 78 includes slots 80 interspersed along the length of
stand-off heat shield 78.
[0037] The size, shape, surface-area, and location of slots 80 can
be designed specifically to a desired thermal gradient control of
stand-off heat shield 78. Integrally forming stand-off heat shield
78 to tube 74 during additive manufacturing process 22 provides a
higher degree of customization and design freedom than traditional
non-additive manufacturing processes allow.
[0038] FIG. 7 is a simplified perspective view of tubular object 82
with ribs 86. Tubular object 82 includes tube 84 and ribs 86
integrally formed to tube 84 during additive manufacturing process
22. Ribs 86 provide a stiffening function to tube 84.
[0039] When tubular object 86 is being used as a strut, tubular
object 82 can experience buckling. High compression loads placed on
tubular object 82 can cause tubular object 82 to fail and buckle.
Ribs 86 stabilize tubular object 82 against buckling under high
compression loads.
[0040] The present disclosure provides ribs 86 integrally formed to
tube 84 during additive manufacturing process 22. Integrally
forming ribs 86 and tube 84 together allows tubular object 82 to
withstand greater amounts of compression loads. Attaching
non-integral support structures to a tubular object creates
additional time and cost into the manufacturing process.
Additionally, the connection between a non-integral support
structure and a tubular object can contain inherent deficiencies
and weaknesses caused by the non-monolithic nature of the
non-integral connection.
[0041] FIG. 8 is a simplified sectional view of tubular object 988
with ribs 92. Tubular object 88 includes tube 90 and ribs 92.
During additive manufacturing process 22, ribs 92 provide
structural support to tube 94. After tubular object 88 is built
with ribs 92 integrally formed within tube 90, ribs 92 additionally
provide structural support to tubular object 88 when tubular object
88 is being used in a post-build functional state. Channels 94 are
disposed in between ribs 92. Closing out the overhead structure
between the ribs at an angle that is less than the build limit
angle eliminates the need for additional support structures. This
design strategy enables open flow passages in curved and otherwise
non-accessible passages from which support structure cannot be
removed.
[0042] Integrally forming ribs 92 to tube 90 during additive
manufacturing process 22 enables the length-wise shape of tubular
object 88 to include non-linear pathways. With traditional
non-additive manufacturing processes, tubular objects following
linear pathways could be machined to include ribs. However, when
tubular object 88 follows a non-linear or serpentine path, ribs 92
are not able to be machined or extruded.
[0043] Additive manufacturing process 22 enables tube 90 to retain
its flow characteristics after the addition of ribs 92. The spaces
between ribs 92 allow for fluid to flow through tube 90.
Additionally, ribs 92 may include perforations with small diameter
holes to allow fluid to pass in between each of ribs 92 and to
maintain pressure equalization so ribs 92 do not get a change in
pressure across each of ribs 92.
[0044] FIG. 9 is a simplified sectional view of tubular object 96
with filter 100. Tubular object 96 includes tube 98 and filter 100.
Filter 100 is integrally connected to tube 98. Filter 100 can be
designed to filter out different sizes of particulates depending on
the fluid and the aircraft engine system tubular object 98 is a
part of. Filter 100 doubles as a support structure for tube 98.
Filter 100, once full with particulate matter, can either be
reversed flushed to remove the particulate matter, or tubular
object 96 containing filter 100 can be disposed of and replaced.
The types of particulates to be filtered using filter 100 may
include metal, carbon, or varnish particles.
[0045] FIG. 10 is a simplified sectional view of tubular object 102
with a compliant matrix 106. Tubular object 102 includes tube 104
which is surrounded by compliant matrix 106. Compliant matrix 106
is integrally connected to tube 104. Skin 108 surrounds and is
integrally connected to compliant matrix 106.
[0046] Skin 108 functions as a heat shield to shield tube 104 from
thermal energy created during in-use conditions. Compliant matrix
106 is compliant and flexible so that compliant matrix 106 and tube
104 do not become overstressed due to thermal gradients or
differentials. Compliant matrix 108 may include a honeycomb or
truss-core structure. Besides providing a heat shielding function,
the combination of compliant matrix 106 and skin 108 increases the
moment of inertia of tubular object 102 and stabilizes tube 104
against buckling. The size and internal structure of compliant
matrix 106 can be designed to perform specific thermal management
based upon the in-use environment of tubular object 102.
[0047] FIG. 11 is a simplified sectional view of tubular object 110
with honeycomb support structure 114. Tubular object 110 includes
tube 112 and honeycomb support structure 114. Honeycomb support
structure 114 is integrally formed to tube 116 during additive
manufacturing process 22. Thin wall 116 surrounds and is integrally
connected to honeycomb support structure 114. Honeycomb support
structure 114 provides a stiffening function for tubular object
110.
[0048] If tube 112 is being used to transport fluid, tube 112 can
experience hoop stress. Honeycomb matrix structure 114 and thin
wall 114 provide structural support to absorb the hoop stress,
among other stresses, experienced by tube 112 during fluid
transport. Additionally, honeycomb support structure 114 and thin
wall 114 generally provide structural support to tubular object
110.
[0049] FIG. 12 is a simplified sectional view of tubular object 118
with spring elements 124. Tubular object 118 includes tube 120 and
honeycomb support structure 122. Honeycomb support structure 122 is
integrally formed to tube 120 during additive manufacturing process
22. Spring elements 124 are positioned radially adjacent to tube
120. Honeycomb support structure 122 is also formed inside of and
integrally connected to spring elements 124. Thin wall 126 is
tubular in shape, and surrounds tube 120, honeycomb support
structure 122, and spring elements 124.
[0050] The arrangement of tube 120, honeycomb support structure
122, spring elements 124, and thin wall 126 performs an energy
absorbing bushing function. Spring elements 124 act as crumple
zones and are enabled to absorb a load spike without tube 120
suffering a catastrophic failure. Additionally, during additive
manufacturing process 22, each of honeycomb support structure 122,
spring elements 124, and thin wall 126 provide overhead support for
building tubular object 118.
[0051] While the invention has been described with reference to an
exemplary embodiment(s), it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment(s) disclosed, but that the invention will
include all embodiments falling within the scope of the appended
claims.
* * * * *