Composite reinforced rotor
11268388 · 2022-03-08
Assignee
Inventors
- David A. Knaul (Glastonbury, CT, US)
- Seung-Woo Choi (Hartford, CT, US)
- Michael Raymond LaFavor (Manchester, CT, US)
- Anthony R. Bifulco (Ellington, CT, US)
Cpc classification
F05D2300/603
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D21/045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/502
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/282
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/322
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D11/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/224
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F01D5/3046
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2240/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D5/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A component of a rotor system is provided and includes a disk and a reinforcing ring. The disk includes an airfoil element, a web extending radially inwardly from the airfoil element and an arm element extending axially from the web. The reinforcing ring is formed of fiber reinforced materials and is disposed to fit about the arm element.
Claims
1. A component of a rotor system, comprising: a disk comprising an airfoil element, a web extending radially inwardly from the airfoil element, a first arm element extending axially forwardly from the web with a first ring retaining feature and a second arm element extending axially aft from the web with a second ring retaining feature; and first and second reinforcing rings formed of fiber reinforced materials and disposed to fit about the first and second arm elements, respectively, wherein the first and second reinforcing rings have conical shapes characterized with uppermost surfaces which are level with the upper edges of the first and second ring retaining features, respectively, and decreasing radial thickness with respectively increasing forward and aft axial distances from the web and the first and second arm elements have conical shapes complementing the conical shapes of the first and second reinforcing rings, respectively.
2. The component of the rotor system according to claim 1, wherein: the airfoil element comprises a platform having a radially interior surface from which the web extends radially inwardly and a radially exterior surface and an airfoil extending radially outwardly from the radially exterior surface, the web comprises a main member extending radially inwardly from the airfoil element, and the component of the rotor system further comprises a bore, which is disposed at a distal end of the main member.
3. The component of the rotor system according to claim 2, wherein the bore radially accommodates a hub or rotor element.
4. The component of the rotor system according to claim 1, wherein the fiber reinforced materials comprise carbon fiber reinforced epoxy.
5. A component of a rotor system, comprising: a disk comprising: an airfoil element; a web extending radially inwardly from the airfoil element; a first arm element extending axially forwardly from the web and comprising a first ring retaining feature; a second arm element extending axially aft from the web and comprising a second ring retaining feature; and a bore, which has a maximum width that is narrower than a minimum width of the airfoil element; and first and second reinforcing rings formed of fiber reinforced materials, the first and second reinforcing rings being disposed to fit about the first and second arm elements, respectively, and to be axially retained by the first and second ring retaining features, respectively, wherein the first and second reinforcing rings have conical shapes characterized with uppermost surfaces which are level with the upper edges of the first and second ring retaining features, respectively, and decreasing radial thickness with respectively increasing forward and aft axial distances from the web and the first and second arm elements have conical shapes complementing the conical shapes of the first and second reinforcing rings, respectively.
6. The component of the rotor system according to claim 5, wherein: the airfoil element comprises a platform having a radially interior surface from which the web extends radially inwardly and a radially exterior surface and an airfoil extending radially outwardly from the radially exterior surface and comprising a tip defining the minimum width of the airfoil element, the web comprises a main member extending radially inwardly from the airfoil element, and the bore is disposed at a distal end of the main member.
7. The component of the rotor system according to claim 5, wherein the fiber reinforced materials comprise carbon fiber reinforced epoxy.
8. A gas turbine engine, comprising compressor and turbine sections and components according to the component of claim 5 disposed in the compressor and turbine sections.
9. The gas turbine engine according to claim 8, wherein the fiber reinforced materials of the reinforcing rings of each component of the rotor system vary with increasing aft positioning along a centerline such that capabilities of the fiber reinforced materials of the reinforcing rings of each component of the rotor system to withstand high-temperatures and high-pressures increase with increasing aft positioning along the centerline.
10. A component of a rotor system having a rotor or hub element, the component of the rotor system comprising: a disk comprising an airfoil element, a web extending radially inwardly from the airfoil element and first and second arm elements extending axially forwardly and aft from the web, respectively, with first and second ring retaining features; a bore disposed at an end of the web; and first and second reinforcing rings formed of fiber reinforced materials and disposed to fit about the first and second arm elements, respectively, wherein the web has a length that positions the bore to radially accommodate the rotor or hub element with radial space between the bore and the rotor or hub element, wherein the first and second reinforcing rings have conical shapes characterized with uppermost surfaces which are level with the upper edges of the first and second ring retaining features, respectively, and decreasing radial thickness with respectively increasing forward and aft axial distances from the web and the first and second arm elements have conical shapes complementing the conical shapes of the first and second reinforcing rings, respectively.
11. The component of the rotor system according to claim 10, wherein: the airfoil element comprises a platform having a radially interior surface from which the web extends radially inwardly and a radially exterior surface and an airfoil extending radially outwardly from the radially exterior surface, the web comprises a main member extending radially inwardly from the airfoil element, and the bore is disposed at a distal end of the main member.
12. The component of the rotor system according to claim 10, wherein the fiber reinforced materials comprise carbon fiber reinforced epoxy.
13. A gas turbine engine, comprising compressor and turbine sections and components according to the component of claim 10 disposed in the compressor and turbine sections.
14. The gas turbine engine according to claim 13, wherein the fiber reinforced materials of the reinforcing rings of each component of the rotor system vary with increasing aft positioning along a centerline such that capabilities of the fiber reinforced materials of the reinforcing rings of each component of the rotor system to withstand high-temperatures and high-pressures increase with increasing aft positioning along the centerline.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
(2)
(3)
(4)
(5)
(6)
(7)
(8) These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
DETAILED DESCRIPTION
(9) A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
(10)
(11) The exemplary gas turbine engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure via several bearing systems 38. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided, and the location of bearing systems 38 may be varied as appropriate to the application.
(12) The low speed spool 30 generally includes an inner shaft 40 that interconnects a fan 42, a low pressure compressor 44 and a low pressure turbine 46. The inner shaft 40 is connected to the fan 42 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 48 to drive the fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a high pressure compressor 52 and high pressure turbine 54. A combustor 56 is arranged in the gas turbine engine 20 between the high pressure compressor 52 and the high pressure turbine 54. The engine static structure is arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The engine static structure 36 further supports the bearing systems 38 in the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
(13) The core airflow is compressed by the low pressure compressor 44 and then the high pressure compressor 52, is mixed and burned with fuel in the combustor 56 and is then expanded over the high pressure turbine 54 and the low pressure turbine 46. The high and low pressure turbines 54 and 46 rotationally drive the low speed spool 30 and the high speed spool 32, respectively, in response to the expansion. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may be varied. For example, geared architecture 48 may be located aft of the combustor section 26 or even aft of the turbine section 28, and the fan section 22 may be positioned forward or aft of the location of geared architecture 48.
(14) The gas turbine engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 46 has a pressure ratio that is greater than about five. In one disclosed embodiment, the gas turbine engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44, and the low pressure turbine 46 has a pressure ratio that is greater than about five 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present disclosure is applicable to other gas turbine engines including direct drive turbofans.
(15) As will be described below, features of a rotor system of a gas turbine engine, such as the gas turbine engine 20 of
(16) With continued reference to
(17) The component 201 includes a disk 210 and a reinforcing ring 230. The disk 210 includes an airfoil element 211, a web 212, an arm element 213 and a bore 2122. The airfoil element 211 includes a platform 2111 that has a radially interior surface 2112 and a radially exterior surface 2113 and an airfoil 2114. The airfoil 2114 extends radially outwardly from the radially exterior surface 2113 of the platform 2111 and includes pressure and suction surfaces, leading and trailing edges at which the pressure and suction surfaces meet and a tip 2115. The tip 2115 can, but is not required to, define a minimum width W.sub.min of the airfoil element 211 as a whole. The web 212 extends radially inwardly from the radially interior surface 2112 of the platform 2111 of the airfoil element 211 and includes a main member 2121. The main member 2121 extends radially inwardly from the radially interior surface 2112 of the platform 2111 of the airfoil element 211. The bore 2122 is disposed at a distal end of the main member 2121 and flares outwardly from the main member 2121. In accordance with embodiments, the bore 2122 has sides that flare outwardly in multiple directions D1, D2 from the main member 2121. The arm element 213 extends axially from the web 212 and can form an internal gas path wall of the gas turbine engine 20. The reinforcing ring 230 is formed of fiber reinforced materials, such as carbon fiber reinforced epoxy (organic or inorganic), and is disposed to fit tightly or with an interference fit about the arm element 213.
(18) The bore 2122 is distinct from the web 212 and provides radial restraint to the rest of the corresponding structure. The web 212 connects the bore 2122 to the airfoil element 211 and a portion of the web 212 can also provide radial restraint. The reinforcing ring 230 can provide additional and efficient radial restraint even while positioned at a more outboard radial position than the bore 2122 because the composite material has lower density and higher strength than typical metals used for rotor features.
(19) Here, it is to be understood that a self-sustaining radius can be defined as a radius where radial growth of the disk 210 equals a radial growth of a free spinning ring. Mass radially inboard of the self-sustaining radius is load carrying and mass radially outboard of the self-sustaining radius does not have sufficient strength to support itself. For a given rotational speed, the self-sustaining radius is a function of material density and strength.
(20) In accordance with embodiments, even with the flaring of the bore 2122 in the multiple directions D1, D2 from the main member 2121, the bore 2122 can have, but is not required to have, a local maximum width W.sub.max that is narrower than the minimum width W.sub.min of the airfoil element 211 as a whole. This characteristic narrowness of the bore 2122 is afforded by the presence of the reinforcing ring 230, which allows for a volume reduction and thus a weight reduction of the bore 2122. In accordance with alternative embodiments, the presence of the reinforcement ring 230 can also permit a radial height of the bore 2122 to be extended outboard with or without characteristic narrowness of the bore 2122.
(21) To an extent that components of a conventional rotor system each have an airfoil element and a web with a bore, each bore in these cases can have a relatively large width as compared to a width of the corresponding airfoil element. This configuration tends to substantially increase a weight of the conventional rotor system and this is especially true where the bore is metallic or a metallic alloy. By contrast, the component 201 of the rotor system 200 of
(22) To the extent that the reinforcing ring 230 is disposed to fit about the arm element 213 with the interference fit, the interference fit results from an inner diameter of the reinforcing ring 230 being slightly smaller than the outer diameter of the arm element 213 and allows the design of the component 201 to take advantage of superior strength properties of the composite materials of the reinforcing ring 230. In particular, since the composite materials of the reinforcing ring 230 can offer load sharing or can take more loading than a tightly fit ring, further bore size reductions and radial location flexibilities can be achieved.
(23) In accordance with further embodiments and as shown in
(24) To the extent that the first and second reinforcing rings 230.sub.1 and 230.sub.2 are disposed to fit about the first and second arm elements 213.sub.1 and 213.sub.2 with the interference fits, the interference fits result from inner diameters of the first and second reinforcing rings 230.sub.1 and 230.sub.2 being slightly smaller than outer diameters of the first and second arm elements 213.sub.1 and 213.sub.2 and allow the design of each component 201 to take advantage of superior strength properties of the composite materials of the first and second reinforcing rings 230.sub.1 and 230.sub.2. In particular, since the composite materials of the first and second reinforcing rings 230.sub.1 and 230.sub.2 can offer load sharing or can take more loading than tightly fit rings, further bore size reductions and radial location flexibilities can be achieved.
(25) With reference back to
(26) Each component 301 of each rotor system includes a disk 310 and a reinforcing ring 330. The disk 310 includes an airfoil element 311, a web 312, an arm element 313 and a bore 3122. The airfoil element 311 includes a platform 3111 that has a radially interior surface 3112 and a radially exterior surface 3113 and an airfoil 3114. The airfoil 3114 extends radially outwardly from the radially exterior surface 3113 of the platform 3111 and includes pressure and suction surfaces, leading and trailing edges at which the pressure and suction surfaces meet and a tip 3115. The tip 3115 can, but is not required to, define a minimum width W.sub.min of the airfoil element 311 as a whole. The web 312 extends radially inwardly from the radially interior surface 3112 of the platform 3111 of the airfoil element 311 and includes a main member 3121. The main member 3121 extends radially inwardly from the radially interior surface 3112 of the platform 3111 of the airfoil element 311. The bore 3122 is disposed at a distal end of the main member 3121 and flares outwardly from the main member 3121. In accordance with embodiments, the bore 3122 has sides that flare outwardly in multiple directions D1, D2 from the main member 3121. The arm element 313 extends axially from the web 312 and can form an internal gas path wall of the gas turbine engine 20. The reinforcing ring 330 is formed of fiber reinforced materials, such as carbon fiber reinforced epoxy (organic or inorganic), and is disposed to fit tightly or with an interference fit about the arm element 313.
(27) In accordance with embodiments, even with the flaring of the bore 3122 in the multiple directions from the main member 3121, the bore 3122 can have, but is not required to have, a local maximum width W.sub.max that is narrower than the minimum width W.sub.min of the airfoil element 311 as a whole. This characteristic narrowness of the bore 3122 is afforded by the presence of the reinforcing ring 330, which allows for a volume reduction and thus a weight reduction of the bore 3122. In accordance with alternative embodiments, the presence of the reinforcement ring 330 can also permit a radial height of the bore 3122 to be extended outboard.
(28) As above, the component 301 of the rotor system 300 of
(29) To the extent that the reinforcing ring 330 is disposed to fit about the arm element 313 with the interference fit, the interference fit results from an inner diameter of the reinforcing ring 330 being slightly smaller than the outer diameter of the arm element 313 and allows the design of the component 301 to take advantage of superior strength properties of the composite materials of the reinforcing ring 330. In particular, since the composite materials of the reinforcing ring 330 can offer load sharing or can take more loading than a tightly fit ring, further bore size reductions and radial location flexibilities can be achieved.
(30) In accordance with further embodiments, the disk 310 can be axially interposed between a forward blade/vane element 340 and an aft blade/vane element 350.
(31) In any case, the disk 310 includes first arm element 313.sub.1 and second arm element 313.sub.2 and the reinforcing ring 330 is provided as first reinforcing ring 330.sub.1 and second reinforcing ring 330.sub.2. The first arm element 313.sub.1 extends axially forwardly from the web 312 and the second arm element 313.sub.2 extends axially aft from the web 312. The first and second arm elements 313.sub.1 and 313.sub.2 can be secured to the web 312 by fastening element 355. The first reinforcing ring 330.sub.1 is disposed to fit tightly or with an interference fit about the first arm element 313.sub.1. The second reinforcing ring 330.sub.2 is disposed to fit tightly or with an interference fit about the second arm element 330.sub.2. In accordance with embodiments, the first and second reinforcing rings 330.sub.1 and 330.sub.2 can have conical shapes (see
(32) To the extent that the first and second reinforcing rings 330.sub.1 and 330.sub.2 are disposed to fit about the first and second arm elements 313.sub.1 and 313.sub.2 with the interference fits, the interference fits result from inner diameters of the first and second reinforcing rings 330.sub.1 and 330.sub.2 being slightly smaller than outer diameters of the first and second arm elements 313.sub.1 and 313.sub.2 and allow the design of each component 301 to take advantage of superior strength properties of the composite materials of the first and second reinforcing rings 330.sub.1 and 330.sub.2. In particular, since the composite materials of the first and second reinforcing rings 330.sub.1 and 330.sub.2 can offer load sharing or can take more loading than tightly fit rings, further bore size reductions and radial location flexibilities can be achieved.
(33) Although
(34) As shown in
(35) While the first and second reinforcing rings 330.sub.1 and 330.sub.2 can be formed of fiber reinforced materials, such as carbon fiber reinforced epoxy (organic or inorganic), the fiber reinforced materials can vary along a centerline (i.e., engine longitudinal axis A) of the high and low pressure sections of each of the compressor and turbine sections 24 and 28 of the gas turbine engine 20 of
(36) The first and second reinforcing rings 230.sub.1 and 230.sub.2 of
(37) It is to be understood that, while the disks 210 and 310 are described herein as having airfoil elements 211 and 311 that are configured as integral blades, the disks 210 and 310 can also be provided as bladed rotors where the airfoils 2114 and 3114 are physically separate components that are assembled to the disks 210 and 310.
(38) With reference to
(39) Although
(40) With reference back to
(41) The additional embodiments can be characterized in that the web 312′ includes outboard portion 610 and flared portion 620 and is substantially shortened so that a radial position of bore 630 can be increased and moved outboard to provide space that radially accommodates the rotor or hub element 601. The rotor or hub element 601 can be a component of the rotor itself, a bearing support or another piece of rotating or static hardware that is coupled or otherwise proximate to the rotor. In this case, the flared portion 620 begins to flare outwardly immediately adjacent to the outboard portion 610 and the corresponding outboard movement of the bore 630 forms a space with sufficient tolerance between the bore 630 and the rotor or hub element 601. The corresponding outboard movement of the bore 630 effectively reduces a weight of the bore 630 and is afforded by the presence of the first and second reinforcing rings 330.sub.1 and 330.sub.2.
(42) Although
(43) Benefits of the features described herein are that, by adding the composite reinforcing rings, a bore of the metal disk of the gas turbine engine rotor system can be reduced in size to thereby save weight and/or a metal bore can be moved radially outwardly in order to provide more space in the bore cavity for other components. That is, the bore in metal disks of gas turbine engine rotor systems is generally positioned as close to the rotor centerline as possible to minimize stress and weight. Normally, the allowable bore position is governed by a “self-sustaining radius,” which is the radius at which the bore material is just able to support its own centrifugal load. In accordance with the description provided herein, however, the low density and high strength of the fiber reinforced composite materials used in the composite reinforcing rings results in a much larger self-sustaining radius. This allows for increased flexibility in component positioning to balance minimized weight and geometric constraints.
(44) The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.
(45) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
(46) While the present disclosure has been described with reference to an exemplary embodiment or embodiments, 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 present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.