JP2011196179A - Method and apparatus for structural outlet guide vane - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide outlet guide vanes (62, 100) for a gas turbine engine.SOLUTION: This outlet guide vanes (62, 100) include: a first flange (64); a second flange (66) arranged radially inward of the first flange; an airfoil (102) extending between the first flange and the second flange, coupled to the first flange and second flange, and having a leading edge portion (130) and a trailing edge portion (132) fabricated from a first material; a filler (150) coupled in a gap formed by the leading edge portion and the trailing edge portion, composed of a first side (203) and a second side (204), and fabricated from a second material different from the first material; a first skin coupled to a first side, and fabricated from a composite material; and a second skin coupled to a second side, and fabricated from the composite material.

Description

  The present invention relates to a gas turbine engine, and more particularly, to a gas turbine engine blade and a manufacturing method thereof.

  At least one known gas turbine engine assembly includes a fan assembly mounted upstream of the core gas turbine engine. In operation, the discharge airflow from the fan assembly is sent downstream to the core gas turbine engine where the airflow is further pressurized. The pressurized air stream is then sent into the combustor where it is mixed with fuel and ignited to generate hot combustion gases. The hot combustion gas is then sent to the turbine, which extracts energy from the combustion gas to provide useful work such as powering the compressor while propelling the aircraft in flight.

  In order to allow air flow from the fan assembly to the core gas turbine engine, at least one known gas turbine engine assembly includes an outlet guide vane assembly. The outlet guide vane assembly is configured to redirect circumferentially flowing air discharged from the fan assembly substantially axially prior to sending the air flow into the core gas turbine engine. In addition to redirecting the fan airflow, the outlet guide vane assembly also provides structural rigidity to the fan frame. Specifically, the outlet guide vane assembly typically includes a plurality of outlet guide vanes coupled to a fan frame. In order to provide the necessary structural rigidity to the fan frame, the known outlet guide vanes are forged as substantially solid vanes using a metallic material.

  However, some known outlet guide vanes are substantially solid so that they can increase the overall weight of the gas turbine engine assembly and cause a reduction in fuel efficiency. Other known guide vanes attempt to use lighter filler material surrounded by metal parts, but they are still too heavy, although they are lighter.

US Pat. No. 7,402,202

  In one aspect, a method for assembling an outlet guide vane includes providing an outlet guide vane frame having a first side and a second side. The outlet guide vane includes a radially inner flange coupled to a radially outer flange at a leading edge. A trailing edge joins the radially inner flange and the radially outer flange behind the leading edge. A cavity is formed between the radially inner flange, the radially outer flange, and the leading and trailing edges. First and second mating surfaces surround the cavity on the first and second sides, respectively. The method further includes coupling a filler portion having a third side and a fourth side into the cavity, and coupling a first skin to the third side and the first mating surface. Bonding a second skin to the fourth side and the second mating surface, wherein at least one of the first skin and the second skin is made of a composite material .

  In another aspect, an outlet guide vane for a gas turbine engine includes a first flange, a second flange disposed radially inward of the first flange, and between the first flange and the second flange. And an airfoil extending to and coupled to the first and second flanges. The airfoil includes a leading edge and a trailing edge. The leading edge and the trailing edge are made of a first material. A filler portion is coupled into a gap formed by the leading edge and the trailing edge. The filler portion has a first side and a second side and is made of a second material different from the first material. A first skin is coupled to the first side and a second skin is coupled to the second side. The first and second skins are made of a composite material.

  In yet another aspect, a gas turbine engine assembly includes a core gas turbine engine, a fan assembly disposed upstream of the core gas turbine engine, and an outlet guide vane assembly having a plurality of outlet guide vanes. The outlet guide vane assembly is disposed downstream of the fan assembly. At least one of the plurality of outlet guide vanes includes an airfoil portion having a leading edge structure and a trailing edge structure each made of a first material, and a filler portion having a first side surface and a second side surface. The filler portion is disposed between the leading edge and the trailing edge and is made of a second material that is different from the first material. The airfoil further includes a first skin coupled to the first side and a second skin coupled to the second side. The first and second skins are made of a composite material.

  1-5 illustrate exemplary embodiments of the methods and apparatus described herein.

1 is a schematic diagram of an exemplary gas turbine engine assembly. FIG. FIG. 2 is a perspective view of a fan frame assembly including a plurality of outlet guide vanes that can be utilized in the gas turbine engine assembly shown in FIG. 1. FIG. 3 is a perspective view of an outlet guide vane that can be used with the fan frame assembly shown in FIG. FIG. 4 is an exploded view of the outlet guide vane of FIG. 3. Sectional drawing of the exit guide blade shown in FIG.

  FIG. 1 is a schematic diagram of an exemplary gas turbine engine assembly 10 having a longitudinal axis 11. The gas turbine engine assembly 10 includes a fan assembly 12 and a core gas turbine engine 13. The core gas turbine engine 13 includes a high pressure compressor 14, a combustor 16 and a high pressure turbine 18. In the exemplary embodiment, gas turbine engine assembly 10 also includes a low pressure turbine 20 and a multi-stage booster compressor 22.

  The fan assembly 12 includes an array of fan blades 24 extending radially outward from the rotor disk 26. The gas turbine engine assembly 10 includes an intake side 28 and an exhaust side 30. The fan assembly 12, the booster 22 and the turbine 20 are coupled to each other by a first rotor shaft 31, and the compressor 14 and the turbine 18 are coupled to each other by a second rotor shaft 32.

  During operation, air flows through the fan assembly 12 and a first portion of the air flow is routed into the booster 22. The pressurized air discharged from the booster 22 is sent into the compressor 14, and the air flow is further pressurized in the compressor 14 and supplied to the combustor 16. Hot combustion products (not shown in FIG. 1) from the combustor 16 are utilized to drive turbines 18 and 20, which are used to drive the fan assembly 12 and booster 22 by the shaft 11. Used. The gas turbine engine assembly 10 is operable in a range of operating conditions between designed operating conditions and off-design operating conditions.

  A second portion of the air flow discharged from the fan assembly 12 is routed through the bypass duct 40 so that a portion of the air flow from the fan assembly 12 bypasses the core gas turbine engine 13. Specifically, the bypass duct 40 extends between the fan casing or shroud 42 and the splitter 44. Accordingly, the first portion 50 of the air flow from the fan assembly 12 is routed through the booster 22 as described above and then into the compressor 14 and the second portion of the air flow from the fan assembly 12. 52 is sent through the bypass duct 40 to provide thrust to the aircraft, for example. The gas turbine engine assembly 10 also includes a fan frame assembly 60 that provides structural support to the fan assembly 12, which is also utilized to couple the fan assembly 12 to the core gas turbine engine 13. .

  FIG. 2 is a front perspective view of the fan frame assembly 60. The fan frame assembly 60 includes a plurality of outlets extending generally radially between the radially outer mounting flange 64 and the radially inner mounting flange 66 and circumferentially spaced around the bypass duct 40. A guide vane 62 is included. The fan frame assembly 60 also includes a plurality of struts 68 coupled between the radially outer mounting flange 64 and the radially inner mounting flange 66. In one embodiment, fan frame assembly 60 is manufactured in the form of an arcuate segment in which flange 64 and flange 66 are coupled to outlet guide vanes 62 and struts 68. In the exemplary embodiment, outlet guide vanes 62 and struts 68 are coupled coaxially within bypass duct 40. Specifically, the outlet guide vanes 62 and struts 68 are each coupled between the flange 64 and the flange 66 at the same axial position as shown in FIG. Optionally, the outlet guide vanes 62 can be coupled downstream of the strut 68 within the bypass duct 40.

  The fan frame assembly 60 is one of the various frames and support assemblies of the gas turbine engine assembly 10 that are used to allow the orientation of the various components within the gas turbine engine assembly 10 to be maintained. Specifically, such a frame and support assembly interconnects stationary components to form a rotor bearing support. The fan frame assembly 60 is configured such that the outlet guide vanes 62 and the struts 68 are spaced circumferentially around the outlet of the fan assembly 12 and extend across the air flow path discharged from the fan assembly 12. Coupled into the bypass duct 40 downstream of the assembly 12.

  In the exemplary embodiment, outlet guide vane 100 includes an airfoil 102 coupled between a radially outer flange 104 and a radially inner flange 106. In this exemplary embodiment, airfoil 102, radial outer flange 104 and radial inner flange 106 are cast or forged as a unitary outlet guide vane 100. Optionally, the radially outer flange 104 and the radially inner flange 106 can be coupled to the airfoil 102 using, for example, a welding or brazing method. In this exemplary embodiment, radially outer and radially inner flanges 104 and 106 are made of metal, and in other embodiments, radially outer and radially inner flanges 104 and 106 are made of composite material. Can do. In still other embodiments, the airfoil 102 may be partially or wholly made of composite material and may have a metal reinforcement attached to the airfoil 102.

  The airfoil 102 includes a first sidewall 110 and a second sidewall 112. In one embodiment, either or both of the first and / or second sidewalls 110 and / or 112 can be shaped to enhance aerodynamic performance. In this exemplary embodiment, the first sidewall 110 is convex and forms the suction side of the airfoil 102, and the second sidewall 112 is concave and the positive pressure of the airfoil 102. Form the side. The side walls 110 and 112 are joined by a leading edge 114 of the airfoil 102 and an axially spaced trailing edge 116. Specifically, the airfoil trailing edge 116 is spaced from the airfoil leading edge 114 downstream in the chord direction. The first and second sidewalls 110 and 112 extend longitudinally or radially outwardly over the wing length from the radially inner flange 106 to the radially outer flange 104, respectively. In this exemplary embodiment, at least a portion of the outlet guide vane 100 is manufactured utilizing a metal material such as, but not limited to, titanium, aluminum and / or metal matrix composite (MMC) material.

  As shown in FIG. 3, the airfoil 102 includes a first assembly surface 120, a second assembly surface 121, a leading edge or spar 130 and a trailing edge or spar 132. Specifically, the airfoil 102 tapers outwardly from the leading edge 114 at least partially toward the trailing edge 116, and further tapers outwardly from the trailing edge 116 at least partially toward the leading edge 114. Have a profile. This profile then tapers inwardly from the leading edge 130 and from the trailing edge 132 to form first and second assembly surfaces 120 and 121. This profile then tapers further inwardly and is surrounded by a first assembly surface 120 on one side of the airfoil and a second assembly surface 121 on the other side of the airfoil. A cavity 140 is formed.

  In this exemplary embodiment, cavity 140 is dimensioned to receive a filler 150 having a first side 203 and a second side 204 that are honeycomb materials. That is, the filler 150 has a thickness 151 that is less than the thickness 144 of the cavity 140 such that when the filler 150 is disposed within the cavity 140, the leading edge 130 and / or the trailing edge 132. Avoid coplanarity. The two laminated portions 201 and 202 are dimensioned to cover the filler 150 between the leading edge 130 and / or the trailing edge 132. The laminated portion 201 is coupled to the first side surface 203 and the first assembly surface 120 so that the laminated portion 201 is substantially flush with both the leading edge 130 and / or the trailing edge 132 and is laminated. Portion 202 is coupled to second side 204 and second assembly surface 121 so that laminated portion 202 is also substantially flush with both leading edge 130 and / or trailing edge 132. In some embodiments, a protective coating 122 such as polyurethane can be applied to the outlet guide vanes 100.

  During manufacture of the outlet guide vanes 100, the outlet guide vanes 100 are cast or forged to include a leading edge 130, a trailing edge 132, and inner and outer flanges 104 and 106. Filler 150 is then coupled into cavity 140 as described above. Next, the laminated portion 201 is bonded to the first side surface 203 and the laminated portion 202 is bonded to the second side surface 204.

  Described herein is an outlet guide vane having a generally hollow inner portion filled with a relatively lightweight material and sandwiched between two laminated sheets, at least some known outlet guide vanes. This is a replacement gas turbine engine. Thus, the exemplary outlet guide vanes described herein still maintain structural integrity while reducing the overall weight of the gas turbine engine assembly, and thus a very challenging engine weight for new applications. Achieve the goal.

  Specifically, the outlet guide vane 100 described herein includes two spars that form the airfoil portion of the outlet guide vane 100. The area between the spar is filled with a honeycomb material that adds rigidity to the airfoil and then sandwiched between two laminated sheets.

  This specification discloses the invention, including the best mode, and is described by way of example to enable those skilled in the art to practice the invention, including making and using the device or system and implementing the method. I have done it. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples have components that have no difference in the wording of the claims, or equivalent components that have no substantial difference from the language of the claims. It belongs to the technical scope described in the claims.

DESCRIPTION OF SYMBOLS 10 Gas turbine engine assembly 11 Longitudinal axis 12 Fan assembly 13 Core gas turbine engine 14 Compressor 16 Combustor 18 High pressure turbine 20 Low pressure turbine 22 Booster 24 Fan blade 26 Rotor disk 28 Intake side 30 Exhaust side 31 1st rotor shaft 32 Second rotor shaft 40 Bypass duct 42 Fan casing or shroud 44 Splitter 50 First portion 52 Second portion 60 Fan frame assembly 62 Exit guide vanes 64 Radially outer mounting flange 66 Radial inner mounting flange 68 Strut 100 Exit guide Airfoil 102 Airfoil 104 Radial outer flange 106 Radial inner flange 110 First sidewall 112 Second sidewall 114 Airfoil leading edge 116 Airfoil trailing edge 120 First assembly surface 121 Second assembly surface 122 Protective coating 130 Front edge or spar 132 Rear edge 140 Cavity 144 Thickness 150 Filler 151 Thickness 201 Laminated portion 202 Laminated portion 203 First side surface 204 Second side surface

Claims (10)

Outlet guide vanes (62, 100) for a gas turbine engine,
A first flange (64);
A second flange (66) disposed radially inward of the first flange;
An airfoil (102) extending between the first flange and the second flange and coupled to the first and second flanges, the leading edge (130) and the rear of the first material. An airfoil (102) having an edge (132);
A filler portion (150) joined within a gap formed by a leading edge and a trailing edge, having a first side and a second side, different from the first material A filler portion (150) made of a second material;
A first skin bonded to the first side surface (203) and made of a composite material;
Outlet guide vanes (62, 100) coupled to the second side surface (204) and comprising a second skin made of composite material.   The outlet guide vane (62, 100) according to claim 1, wherein the first material comprises a metallic material and the second material comprises a honeycomb material.   The outlet guide vane (62, 100) of claim 1, wherein at least one of the radially inner flange (106), the radially outer flange (104), and the airfoil (102) comprises a composite material.   The outlet guide vane (62, 100) according to claim 1, wherein the first material is aluminum.   The outlet guide vane (62, 100) according to any one of claims 1 to 4, further comprising a protective coating (122) provided on the outlet guide vane.   The outlet of claim 1, wherein the first flange (104), the second flange (106) and the airfoil (102) comprise at least one of a cast unitary structure outlet guide vane and a forged unitary structure outlet guide vane. Guide vanes (62, 100). A core gas turbine engine (13);
A fan assembly (12) located upstream of the core gas turbine engine and comprising a plurality of fan blades;
A gas turbine engine assembly (10) that is located downstream of the fan assembly and comprises an outlet guide vane assembly comprising a plurality of outlet guide vanes (62, 100), wherein at least one of the plurality of outlet guide vanes is
An airfoil (102) having a leading edge structure and a trailing edge structure, each consisting of a first material;
A filler portion (150) comprising a first material and a second side surface, the filler portion (150) comprising a second material different from the first material, disposed between the front edge and the rear edge;
A first skin bonded to the first side surface (203) and made of a composite material;
A gas turbine engine assembly (10) comprising a second skin coupled to the second side (204) and made of a composite material.   The gas turbine engine assembly (10) of claim 7, wherein the airfoil (102) further comprises a separable assembly.   The gas turbine engine assembly (10) of claim 7, wherein the first material comprises a metallic material and the second material comprises a honeycomb material.   The gas turbine engine assembly (10) of claim 7, wherein at least a portion of the airfoil (102) is made of a composite material.

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