SHAFT COMPONENT AND METHOD FOR PRODUCING A SHAFT COMPONENT
20230054031 · 2023-02-23
Assignee
Inventors
Cpc classification
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C3/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2240/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/614
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2360/23
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2240/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/6034
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/40311
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
International classification
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A shaft component, which in particular can be connected or is connected to the input or output side of a gear box in a gas turbine engine, in particular an aircraft engine, wherein the shaft component has at least two regions comprising fiber reinforced plastic, with fibers in the at least two regions differing in their composition, their geometric properties, their density, their radial position, their axial position and/or in their fiber orientation in the shaft component.
Claims
1-22. (canceled)
23. A shaft component, which in particular can be connected or is connected to the input or output side of a gear box in a gas turbine engine, wherein the shaft component has at least two regions comprising fiber reinforced plastic, with fibers and/or their matrix in the at least two regions differing in their composition, their geometric properties, their density, their radial position, their axial position and/or in their fiber orientation in the shaft component.
24. The shaft component of claim 23, wherein in at least one of the regions, the fibers are arranged in an angular range of +/-40° to 50° in relation to the main axis of rotation of the shaft component.
25. The shaft component of claim 23, wherein in at least one of the regions the fibers are arranged in an orientation range of about 0° in relation to the main axis of rotation of the shaft component.
26. The shaft component of claim 23, wherein, in at least one of the regions the fibers are arranged in an angular range 60 to 90° in relation to the main axis of rotation of the shaft component.
27. The shaft component of claim 23, wherein a region which is adjacent to another region with a different fiber orientation, is a transitional zone while the fiber changes angle, in particular the transitional zone is configured in such a way that more than 90% of the fiber angle change is contained within an axial extant no greater than 10% of the shorter of the two adjacent regions.
28. The shaft component of claim 23, wherein the shaft component has a non-constant or non-uniform diameter along the axis of rotation.
29. The shaft component of claim 28, wherein shaft component comprises undulations.
30. The shaft component of claim 23, wherein the ratios between resin and fibers are different in the at least two different regions.
31. The shaft component of claim 23, wherein fiber bundle counts and fiber diameters are different in the at least two different regions.
32. The shaft component of claim 23, wherein the angle of the fiber arrangement varies radially in the at least two different regions.
33. The shaft component of claim 23, wherein at least one woven material is used in least one of the two different regions.
34. The shaft component of claim 23, wherein the ratio between the largest diameter and the smallest diameter of the shaft component is less than 1.1.
35. The shaft component of claim 23, wherein at least one first region comprising fibers with orientations going from 40° to 50° to 65° to 90° and at least one second region with fibers with orientations going from 0° to 50° and the at least one first region being adjacent to the at least one second region.
36. The shaft component of claim 23, wherein the fiber-reinforced plastic comprises carbon fibers, metal filaments, synthetic fibers or a mixture thereof.
37. The shaft component of claim 23, wherein the fiber-reinforced plastic comprises aramid fibers, ceramic fibers or a mixture of aramid fibers and ceramic fibers.
38. A method for producing a shaft component, which can be connected or is connected to the input or output side of a gear box in a gas turbine engine, wherein fibers are incorporated in a matrix, the fibers and/or their matrix being incorporated in the shaft component so that in at least two regions differ in their composition, their geometric properties, their density, their radial position, their axial position and/or in their fiber orientation in the shaft component.
39. The method of claim 38, wherein a winding method, a braiding method, a Tailored Fiber Placement method or a combination of those methods is used for incorporating the fibers in the matrix or in the shaft component.
40. The method of claim 38, wherein the fiber-reinforced plastic comprises carbon fibers, metal filaments, synthetic fibers or a mixture thereof.
41. The method of claim 40, wherein the fiber-reinforced plastic comprises aramid fibers, ceramic fibers or a mixture of aramid fibers and ceramic fibers.
42. A gas turbine engine for an aircraft, the gas turbine engine comprising: an engine core comprising a turbine, a compressor, and a core shaft connecting the turbine to the compressor; a fan, which is positioned upstream of the engine core, wherein the fan comprises a plurality of fan blades; and a gear box, which can be driven by the core shaft, wherein the fan can be driven by means of the gear box at a lower rotational speed than the core shaft, wherein a shaft component of claim 23 is connected to the gear box as part of a drive shaft for the fan.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] The present disclosure will be explained in more detail on the basis of exemplary embodiments with reference to the accompanying drawings in which:
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[0070] The following table lists the reference numerals used in the drawings with the features to which they refer:
TABLE-US-00001 Ref no. Feature A Core airflow B Bypass airflow P Parallel offset 9 Main axis of rotation 10 Gas turbine engine 11 Enine core 12 Air inlet 14 Low-pressure compressor 15 High-pressure compressor 16 Combustion device/equipment 17 High-pressure turbine 18 Bypass thrust nozzle 19 Low pressure turbine 20 Core thrust nozzle 21 Engine nacelle 22 Bypass duct 23 Fan 24 Stationary supporting structure 26 Shaft
TABLE-US-00002 Ref no. Feature 27 Connecting shaft 28 Sun gear 30 Gear box 32 Planet gears 34 Planet carrier 36 Linkage 38 Ring gear 40 Linkage 50 Shaft component 51 First region comprising fiber reinforced plastic 52 Second region comprising fiber reinforced plastic 53 Third region comprising fiber reinforced plastic 54 Undulation/bellow 60 Fiber 71 First undulant section 72 Second undulant section 73 Third undulant section
DETAILED DESCRIPTION OF THE DISCLOSURE
[0071] Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.
[0072]
[0073] During operation, the core air flow A is accelerated and compressed by the low-pressure compressor 14 and directed into the high-pressure compressor 15, where further compression takes place. The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion device 16, where it is mixed with fuel and the mixture is combusted. The resultant hot combustion products then expand through, and thereby drive, the high-pressure and low-pressure turbines 17, 19 before being expelled through the core thrust nozzle 20 to provide some thrust force. The high-pressure turbine 17 drives the high-pressure compressor 15 by means of a suitable connection shaft 27. The fan 23 generally provides the major part of the propulsive thrust. The epicyclic planetary gear box 30 is a reduction gear box.
[0074] An exemplary arrangement for a geared fan gas turbine engine 10 is shown in
[0075] Note that the terms “low-pressure turbine” and “low-pressure compressor” as used herein may be taken to mean the lowest-pressure turbine stage and lowest-pressure compressor stage (i.e. not including the fan 23) respectively and/or the turbine and compressor stages that are connected together by the connecting shaft 26 with the lowest rotational speed in the engine (i.e. not including the gear-box output shaft that drives the fan 23). In some literature, the “low-pressure turbine” and “low-pressure compressor” referred to herein may alternatively be known as the “intermediate-pressure turbine” and “intermediate-pressure compressor”. Where such alternative nomenclature is used, the fan 23 can be referred to as a first, or lowest-pressure, compression stage.
[0076] The epicyclic planetary gear box 30 is shown by way of example in greater detail in
[0077] The epicyclic planetary gear box 30 illustrated by way of example in
[0078] It is self-evident that the arrangement shown in
[0079] Accordingly, the present disclosure extends to a gas turbine engine having any arrangement of types of gear box (for example star or epicyclic-planetary), supporting structures, input and output shaft arrangement, and bearing locations.
[0080] Optionally, the gear box may drive additional and/or alternative components (e.g. the intermediate-pressure compressor and/or a booster compressor).
[0081] Other gas turbine engines to which the present disclosure can be applied may have alternative configurations. For example, engines of this type may have an alternative number of compressors and/or turbines and/or an alternative number of connecting shafts. As a further example, the gas turbine engine shown in
[0082] The geometry of the gas turbine engine 10 and components thereof, is/are defined by a conventional axis system, comprising an axial direction (which is aligned with the axis of rotation 9), a radial direction (in the bottom-to-top direction in
[0083] In the following, several embodiments of shaft components 50 to be used in connection with the input and/or output side of the gear box 30 are described in an exemplary way.
[0084] The figurative representations in
[0085] For the sake of simplicity, all shaft components 50 in
[0086] The shaft component 50 can also comprise e.g. conical parts or flanges. At the ends of the shaft components 50 (not shown here), metallic end fittings can be positioned. The attachment of the end fittings can effected by adhesive and/or mechanical means. The shaft coupling can be e.g. a spline or a curvic coupling.
[0087] By deliberately varying the properties of the fibers e.g. in their axial position along the shaft component 50, at least two regions 51, 52, 53 are created in the shaft component 50 having different mechanical properties. This is a deliberate introduction of an anisotropy along the axial direction of the shaft component 50 that can be tailored to achieve specific design objectives.
[0088] As shown in
[0089] It is possible that e.g. the shaft component 50 has uniform fiber properties but for two regions 51, 52 distributed along the axis. As shown in the context of
[0090] The regions 51, 52, 53 can differ e.g. in the orientation of the fibers 60 resulting in differences in the behavior. In addition or alternatively, different fibers 60 could be used. Different geometric properties (e.g. fiber diameters, fiber lengths) have an effect on the mechanical properties of the shaft component 50.
[0091] Also, the ratio of resin and fibers 60 can be different in different regions 51, 52, 53 of the shaft component 50.
[0092] In
[0093] In
[0094] It is not mandatory, that different regions 51, 52, 53 have to have the same axial lengths, as shown in
[0095] In
[0096] In
[0097] In
[0098] Since the mechanical properties of the shaft components 50 can be mechanically tailored by using regions 51, 52, 53 with different properties, the sizing of the bellows 54 (also responsible for mechanical properties of the shaft component) can be reduced or even substituted by the regions 51, 52, 53 having different properties each.
[0099] In following, some of the different properties, to be used in different regions 51, 52, 53 are listed in an exemplary way. [0100] Regions 51, 52, 53 having different fiber directions in different layers - parallel and perpendicular to shaft axis 9, resulting in different stiffness. [0101] Regions 51, 52, 53 having different fiber directions in different layers - at different angles and hand of twist relative to the shaft axis 9, resulting in different stiffness. [0102] Regions 51, 52, 53 having different fiber packing densities in different layers resulting in different density/stiffness. [0103] Regions 51, 52, 53 having different fiber materials in different layers different resulting in different strength/stiffness. [0104] Regions 51, 52, 53, having different fiber diameters or cross sections in different layers resulting in different stiffness/second moment of inertia. [0105] Regions 51, 52, 53 having a combination of woven fiber ribbon and individual fibers in different layers resulting in a combination of multidirectional and unidirectional properties. [0106] Regions 51, 52, 53 having a combination of fiber or ribbon wound into a shaft form while ‘dry’, then impregnated with the resin matrix. [0107] Regions 51, 52, 53 having a fiber or ribbon wound into a shaft form when preimpregnated with resin, then cured using heat.
[0108] Even though the embodiments of the shaft component 50 have been exemplary shown in the context of a geared turbo engine 10, the shaft components 50 can also be used in other contexts. Similar concepts may be of use on other components/engine designs where tailored stiffness is required, for example flexible couplings or shafts in the accessory drive train, e.g. to drive the accessory gearbox, oil pumps, fuel pumps, generators. These may be positioned on the engine main line, or off the engine mainline (e.g. on the intercase or fan case).
[0109] In the following some embodiments are described in which certain regions 51, 52, 53 have a certain fiber orientation.
[0110] The following table shows assignments of different composite shaft sections (Type A to E) with certain fiber orientations (i.e. ranges of angles).
TABLE-US-00003 Section type Fiber Orientation (from shaft central axis projected into composite section) Axial Stiffness and Strength Property Bending Stiffness and Strength Property Torsional Stiffness and Strength Property A 0° to 25° especially 0° Very High Very High Very Low B 25° to 40° High High Medium C 40° to 50° especially 45° Medium Medium Very High D 50° to 65° Low Low Medium E 65° to 90° especially 90° Very Low Very Low Very Low
[0111] Each of the different fiber orientations reacts differently to axial, bending and torsional loads, as indicated in above table.
[0112] The axial and bending stiffness are highest with relatively small fiber orientation angles and decreases with increasing fiber orientation angles.
[0113] The torsional stiffness is highest around a fiber orientation angle of 45° and falls off towards smaller and higher fiber orientation angles.
[0114] When describing fiber orientations, only one of the matched pair of orientations is listed. The region will be made of fibers at both the quoted angle and its matched pair with a negative sign.
[0115] So a region of e.g. section type C with 45° refers to a shaft region with an equal amount of fiber in the +45° and the -45° directions.
[0116] These pair of angles can be considered as right handed helix and left handed helix angles. The equal amount of fiber is important as it produces a composite with a symmetric
[0117] The fiber orientations of 0° and 90° are exceptions to this as for these two angles, the negative value is the same as the positive. Hence 0° is with all the fibers axially aligned and 90° is with all the fibers circumferentially aligned to the shaft.
[0118] Note that although both the stiffness and strength of the various section types listed in the table above follow the trend as tabulated, the proportions of the stiffness and strength changes will differ in magnitude.
[0119] Each region 51, 52, 53 does not have to be exclusively composed of fibers in one pair of orientations, so a composite can be made with a mixture of different angles in different layers to give some merged combination of the stiffness and strength properties.
[0120] It is possible that a composite shaft component 50 can been designed with just one region 51 (e.g. designated A-C or B-C) formed from a mixture of section type A or B to give adequate bending stiffness to increase the modal frequency and avoid whirling vibrations, combined with a section type C to give adequate torsional strength. The total composite thickness and the mixture proportions of a given design would be determined to meet the specific requirements of the shaft.
[0121] In the upper half of
[0122] In the lower half of
[0123] Starting from left, the centerline is relatively straight till the first undulant section 71 as the shaft component is relatively stiff. The first and second undulant sections 71, 72 reduce the stiffness locally, so that the center line comprises two slightly curved sections in the respective undulant sections. Towards the right, the third undulant section 73 introduces a further localized reduction of the stiffness, causing a further curved section in the center line.
[0124] Embodiments considered here, differ by utilizing different regions 51, 52, 53 composed of different section types within the shaft component 50.
[0125] This is shown for example in
[0126] Here the shaft component comprises two regions 51, 52 (designated C-E) at either end of a region 53 (designated A-C or B-C) creating a shaft component 50 design which retains adequate torsional strength and stiffness to avoid whirling vibrations, but with a tailored bending stiffness to isolate the gearbox from damaging mis-alignments and bending moments. This has the same or similar effect as the design of the shaft component 50 in
[0127] While the regions designated C-E have low or very low axial stiffness properties, they only contribute to the overall stiffness of the shaft in proportion to their length, allowing the design to meet the overall target axial stiffness.
[0128] Similarly, the central region 53 designated A-C or B-C maintains the natural frequency at a high value and avoids any damaging whirling vibrations. The two regions 51, 52 designated C-E both deform in a pivoting style motion to allow any mis-mismatch between the ends of the shaft component 50 while isolating the gearbox from damaging bending moments.
[0129] By designing composite shafts with the methods described above, the axial and torsional stiffness’ can be maintained while producing significant reductions in the bending moment shaft stiffness, without the need to include reductions in stiffness with large geometric features as shown in regions 51, 52. The composite shaft can actually have a plain cross-section without any significant disturbance.
[0130] It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present disclosure in any way. Also, those skilled in the art will appreciate that other aspects of the disclosure can be obtained from a study of the drawings, the disclosure and the appended claims. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. Various features of the various embodiments disclosed herein can be combined in different combinations to create new embodiments within the scope of the present disclosure. In particular, the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein. Any ranges given herein include any and all specific values within the range and any and all sub-ranges within the given range.