Method for manufacturing turbomachine member ring supports

Abstract

Turbomachine member ring supports extending over sectors of a circle can be constructed from at least one thick flat metal sheet that is curved and welded to form a cylindrical shroud and then formed by pressing into a conical shroud, the outer face of which is machined in order to shape the profile of a mounting rail therein, and the shroud is sectioned in order to divide it into the sectors. The supports have better cohesion and the manufacture thereof is simple and reliable compared with traditional manufacture using bossing of thin metal sheets for joining together the main portions of the supports. The application also relates to a use with stator rings of a turbomachine member that are provided with an abradable lining.

Claims

1. A method of manufacturing ring supports for a member of a turbomachine, said supports extending around angular sectors of a cone, comprising a sealing lining on an inner face of the cone and a mounting rail on an outer face of the cone opposite the inner face, the mounting rail comprising a groove limited by at least one collar protruding in an outer radial direction of the cone, the method comprising: a) starting from at least one plane metal sheet, b) bending and welding the at least one metal sheet to form a closed cylindrical shroud, c) bending the cylindrical shroud in a tooling to form a conical shroud, d) cutting the conical shroud to divide the conical shroud into said angular sectors, e) wherein the mounting rail is formed, after said bending of the cylindrical shroud and before the cutting of the conical shroud, by machining the outer face of the support to excavate the groove and carve the at least one collar out of a material of the conical shroud, and wherein the tooling in which the cylindrical shroud is shaped comprises a circular row of jaws with radial expansion and an outer static ring surrounding the circular row.

2. The manufacturing method according to claim 1, wherein the bending and shaping are done cold.

3. The manufacturing method according to claim 1, wherein the cylindrical shroud is shaped in the tooling in two jaw expansion passes, and is turned by an angular step between the jaws between the two expansion passes.

4. The manufacturing method according to claim 1, wherein said at least one plane metal sheet comprises at least two plates.

5. The method of claim 1, wherein the conical shroud is a biconical shroud, and the biconical shroud is cut to divide it into two circles of the supports, by removing a center of the biconical shroud, before cutting the two circles of the supports into said angular sectors.

6. The method of claim 1, wherein the outer face is excavated at the center with discontinuous milling operations.

7. The method of claim 1, wherein a recess is machined at an end of the inner face, in which a second mounting rail, comprising a central concave part facing an axial direction of the turbomachine, is to be inserted by brazing.

8. The method of claim 1, wherein the cutting includes cutting in a radial direction to form the angular sectors.

9. The method of claim 1, wherein the cutting includes separating the angular sectors from each other.

10. A method of manufacturing ring supports for a member of a turbomachine, said supports extending around angular sectors of a cone, said supports comprising a sealing lining on an inner face of the cone and a mounting rail on an outer face of the cone opposite the inner face, the mourning rail comprising a groove extending between two collars protruding in an outer radial direction of the cone, the method comprising: a) starting from at least one plane metal sheet, b) bending and welding the at least one metal sheet to form a closed cylindrical shroud, c) bending the cylindrical shroud in a tooling to form a conical shroud, d) cutting the conical shroud to divide the conical shroud into said angular sectors, e) wherein the mounting rail is formed, after said bending of the cylindrical shroud and before said cutting of the conical shroud, by machining the outer face of the support by turning the conical shroud in a lathe to excavate the groove and excavate the outer face at a center, so as to carve the two collars out of a material of the conical shroud.

11. The method of claim 10, wherein the conical shroud is a biconical shroud, and the biconical shroud is cut to divide the biconical shroud into two circles of the supports, by removing a center of the biconical shroud, before cutting the two circles of the supports into said angular sectors.

12. The method of claim 10, wherein the outer face is excavated at the center with discontinuous milling operations.

13. The method of claim 10, wherein a recess is machined at an end of the inner face, in which a second mounting rail, comprising a central concave part facing an axial direction of the turbomachine, is to be inserted by brazing.

14. The method of claim 10, wherein the bending and shaping are done cold.

15. The method according to claim 10, wherein said at least one plane metal sheet comprises at least two plates.

16. The method according to claim 10, wherein the cutting includes cutting in a radial direction to form the angular sectors.

17. The method according to claim 10, wherein the cutting includes separating the angular sectors from each other.

18. The method of claim 10, wherein the tooling in which the cylindrical shroud is shaped comprises a circular row of jaws with radial expansion and an outer static ring surrounding the circular row.

19. The method of claim 18, wherein the cylindrical shroud is shaped in the tooling in two jaw expansion passes, and is turned by an angular step between the jaws between the two expansion passes.

Description

(1) The different aspects of one purely illustrative embodiment of the invention will now be described in more detail with reference to the following figures:

(2) FIG. 1 is a representation of a known support;

(3) FIG. 2 illustrates the flat plate used at the beginning of the invention;

(4) FIG. 3 illustrates bending this plate into a cylindrical shroud;

(5) FIGS. 4 and 5 illustrate two views of the stamping press that creates a biconical shroud;

(6) FIG. 6 illustrates the choice of stamping in two passes;

(7) FIG. 7 illustrates how machining is done;

(8) FIGS. 8 and 9 represent two views of a support according to the invention;

(9) and FIGS. 10 and 11 illustrate the lateral ends of the known support and a product support according to the invention, respectively.

(10) FIG. 1 represents a ring support for a member of a turbomachine such as a turbine made by welding and brazing of thin plates making use of a known technique. A main plate 1 has a more or less regular conical shape around an angular sector and comprises an inner face onto which an abradable honeycomb sealing lining 2 is fixed; there is an outer mounting rail 3 composed of a second thin plate on its outer face, curved so as to have two projecting collars 4 and 5, rising radially outwards, with an intermediate depression 6. There is another mounting rail 7, also with a U-section but for which the central concave part is facing along the axial direction of the machine, at an axial end. The rails 3 and 7 are both brazed to the main plate 1. As seen above, it may be complicated to manufacture the support and its strength may be unpredictable in the long term under the many thermal cycles applied to it. FIG. 10 illustrates the particular form of the support at each of its angular ends: two other plates 25 and 26 are welded to it on the outer face of the main plate 1, so as to thicken the section of the support so that a slit 27 can be formed on its side face, a portion of the sealing plate fitting into the slit 27 and covering the gap between the two supports when the support is mounted and adjacent to a similar support. These plates 25 and 26 make manufacturing of the support more complicated. FIG. 1 and the other figures show the longitudinal X axis of the machine on which the supports will be mounted, in circles around this X axis.

(11) We will now give a description of the invention starting with FIG. 2. The raw material consists of a flat plate 8, or a small number of such plates 8. The plate 8 or plates 8 pass through a bending installation in which they are bent so as to obtain a cylindrical shroud 9 (FIG. 3), that is made continuous by closing the circle by welding, after trimming the end edges. It is preferable to use the smallest possible number of plates 8 and this is why a good compromise may be to use three plates 8, each of which is curved in a half of a circle or a third of a circle; however, a single plate can be curved into an entire circle despite its thickness.

(12) The next step represented in FIGS. 4 and 5, consists of shaping the cylindrical shell 9 into a conical shroud, and more advantageously a biconical shroud 10, so as to follow the change of radius in the turbine. The cylindrical shroud 9 is put into equipment including a stamping tool such as a press including a circular row of jaws 11, with concomitant radial displacement that are pushed together by a central conical broach 23, and a static ring 12 that faces them and is concentric with them. The biconical shape is obtained by the static ring being concave and the jaws 11 projecting at the centre. In moving the jaws 11 towards the ring 12, the cylindrical shroud is deformed into the required biconical shape. Stamping may comprise an expansion part that increases the radius of the biconical shroud 10. It will be observed that the ring 12 is formed from two superposed stages 12a and 12b, that can be separated by lifting the upper stage 12a to insert and then remove the shrouds 9 or 10.

(13) It is useful to avoid excessive force unbalances that can occur during this operation, that can be cause of manufacturing dimensions not being respected. The circular shape of the press makes it possible to equalise forces in the angular direction; and unbalanced forces in the axial direction of the shroud 9 or 10 can be cancelled out if the tool is symmetrical on opposite sides of a median plane, as it is in this case, due to the biconical profile of the jaws 11 and the ring 12.

(14) However, it should be noted that all steps of the method can be done cold due to the small deformation applied to the material, both in the bending step (the deformation being distributed over a long length) and the shaping step into a biconical shape.

(15) This shaping by stamping step will usually be made in two passes due to discontinuities between the jaws 11 along the circular row; after a first pass, the biconical shell 10 will be moved by one angular step between jaws 11 corresponding to a few degrees, so as to move each portion of the periphery in front of one of the jaws 11 after each pass (FIG. 6) and thus to make the biconical shroud uniformly circular, eliminating any flat portions remaining between the jaws 11 after the first pass.

(16) FIG. 7 illustrates the shape of the biconical shroud 10 superposed on a pair of supports 19 to be obtained. Manufacturing operations will now consist of machining and particularly turning in a conventional numerically controlled machine like a lathe. As mentioned above, the symmetric biconical shape of the shroud 10, designed to equalise forces in the axial direction of the stamping press, is designed to form a circle of supports 19 in each of its halves. The biconical shell 10 comprises an inner surface 13 and an outer face 14. The inner face 13 remains essentially unmachined over at least most of its surface, except for the excavation of a recess 15 at one end of each support 19 in which the rail 7 will fit, that is unchanged from the previous design. On the other hand, the outer face 14 will be completely machined since the support dimensions 19 must be precise and the surface condition must be good at this location, which is not the case for most of the inner face 13 on the sealing lining 2 is fitted and is therefore not visible; in particular, a groove 16 will be excavated corresponding to the concave shape of the rail 3 in the previous design, and a collar 17 similar to the collar 5 will be formed at the end of each of the supports 19. The last operations will consist of chopping off the ends 20 of the biconical shroud 10, in a first step to divide it so as to separate the two circles of supports 19, by completely removing the centre 21, and cutting the two circles of supports 19 into angular sectors so as to separate the supports 19 from each other. Slits 27 are made at the lateral ends in a final step, directly at the mid-thickness of the plate (FIG. 11).

(17) FIGS. 8 and 9 illustrate one of the supports 19 finally obtained after having installed the rail 7 and the sealing lining 2. The portion including the groove 16 and the collar 17 carved in the mass of the biconical shroud 10, has the same dimensions as the concave part 6 and the collar 5 according to the prior design, such that the support 19 can perfectly replace the support 1. Note that the support 19 will be heavier because it is formed from a plate 8 thicker than the plate of the support 1. However, this disadvantage can be attenuated by excavating its outer face by milling at the centre, without reaching the groove 16. Milling operations 22 are discontinuous and are not applied at the edges of the supports 19.

(18) Replacing the add-on rail 3 by a single-piece portion of the support 19 contributes to improving its cohesion, and it reliably produces correct dimensions. Thus, remachining work is minimised.