RU2804167C1 - Method for manufacturing a pipeline of complex configuration for a gas turbine engine by an additive method - Google Patents

Abstract

FIELD: engine production.

SUBSTANCE: method for manufacturing a pipeline of complex configuration for a gas turbine engine by the additive method includes the creation of a three-dimensional model of the pipeline (1) based on the initial data. The method comprises the stage of laying a pipeline route with account for the bypass zones, the stage of creating a library of parts, assembly units of the pipeline and fastening elements, the stage of assessing the process feasibility of manufacturing the pipeline, and the stage of forming the final model of the pipeline. The stage of laying the pipeline route (1), with account for the bypass zones, includes determining the minimum clearance between the engine and the application object along a pre-built minimum trajectory between the start and end points of the pipeline route. Contours of passage sections (6) of the pipeline are created. A preliminary tracing of the pipeline contour (1) is carried out by connecting the reference points (7) of the outer contour of the pipeline sections, ensuring minimum gaps between the pipeline route (1) and the application object or the engine, taking into account the preliminary hydraulic calculation of the line based on the ratioΔ R_p.c <Δ R_p.c.all, whereΔ R_p.c is actual pressure loss,Δ P_p.c.all is allowable pressure loss in the line. The geometry of the pipeline (1) is profiled along the contour of the installation site. The thickness of the pipe wall is determined, then the pipeline is calculated for strength at various points. A central stiffener is designed in places (3) of the junction of the pipeline (1). The stage of forming the final pipeline model (1) includes the final version of the pipeline routing, taking into account the three-dimensional hydraulic calculation. Then, in accordance with the created three-dimensional model, the parts of the pipeline route are manufactured by an additive method, followed by their assembly.

EFFECT: reducing the length of the pipeline route of the gas turbine engine.

1 cl, 7 dwg

Description

The invention relates to the field of engine building, namely to a method for manufacturing pipelines of a complex spatial configuration of a gas turbine engine, and can find application in aviation technology.

The manufacture and installation of pipelines for a gas turbine engine (GTE) is a complex technological task associated with the placement of pipelines in a limited space due to the dense layout of the engine.

The development of additive technologies makes it possible to improve methods for manufacturing parts with complex configurations.

The use of additive growth technology makes it possible to increase the cost-effectiveness of manufacturing parts compared to casting, deformation and machining technologies, which is a pressing problem in aircraft engine manufacturing. A distinctive feature of this method is the layer-by-layer formation of the part. The process of creating a part is carried out according to a given 3D computer model, which ensures high accuracy of the manufactured part.

Selective laser sintering additive manufacturing technology for manufacturing aviation products is the fastest additive manufacturing technology. Lasers used to sinter powder have much faster scanning speeds and are more precise than layer joining methods used in other processes.

An air duct manufactured by selective laser fusion is known (utility model patent No. 210922, application 2021131633, filing date 10.28.2021, SPK B22F3/105; F24F13/0254; F24F13/02; B60H1/00; B60H1/24; B60H20 01/ 00078) having a complex geometric shape.

There is a known method and computer model for the additive manufacturing of air duct structures (US 2017284676, priority date 03/30/2016, applicant SIEMENS ENERGY INC, METHOD AND COMPUTER-READABLE MODEL FOR ADDITIVELY MANUFACTURING INJECTOR ASSEMBLY OR DUCTING ARRANGEMENT INCLUDING SUCH INJECTOR ASSEMBLIES), including creation of a machine-readable 3D model assembly defining a complex duct configuration, wherein the additive manufacturing technology is a technology selected from the group consisting of laser sintering technology, direct metal laser sintering (DMLS) technology, selective laser melting (SLM) technology, electron beam sintering (EBS) technology ) and electron beam sintering technology. The beam melting method (EBM), further comprising defining additional injector assemblies in the duct system model, wherein said injector assembly and the additional injector assemblies comprise a plurality of circumferentially arranged combustion stage injector assemblies. Computer-readable model, machine-readable model is a computer-aided design (CAD) model.

There is a known method and computer model for the additive manufacturing of air duct structures (US 2018039254, priority date 02/08/2018; applicant SIEMENS AG [DE], METHOD AND COMPUTER-READABLE MODEL FOR ADDITIVELY MANUFACTURING DUCTING ARRANGEMENT WITH INJECTOR ASSEMBLIES FORMING A SHIELDING FLOW OF AIR) including the creation three-dimensional model of the air duct and production of the air duct using additive manufacturing technology in accordance with the created three-dimensional model.

The proposed methods can be used in the manufacture of pipelines of complex configurations, but do not solve the problem of optimizing the geometric parameters of the engine pipeline route.

There is a known method for modeling three-dimensional design in computer systems (RF patent 2263966, application No. 2004105560, IPC G06T17/00, filing date 02/24/2004, publication date 11/10/2005 Bulletin No. 31) including computer design and can be used in the design of multi-component products with using three-dimensional computer modeling systems.

The described design method is outdated, since modern computer systems have sufficient performance to construct all elements of parts, and not just the outer surfaces as described in the patent.

There is a known method for determining the shape of a pipe (RF patent 2578175, application No. 2014153274, date 12/25/2014, IPC G01B17/00) including the formation of a mathematical model of the pipe at the installation site.

The disadvantage of the described method is the impossibility of its use when designing a gas turbine engine pipeline due to the fact that the engine has a circular cross-section and the pipeline goes around its contour; it is impossible to position the antennas while observing the conditions of line of sight between the control points.

The closest solution to the claimed method is a method for designing a model of a pipeline of complex configuration for a pipe bender (Article “Design, production and testing of aircraft engines”, authors S.V. Titenkov, V.Yu. Zhuravlev, pp. 217 - 219) including creation of a three-dimensional pipeline model based on initial data, containing the stage of laying the pipeline route taking into account bypass zones, the stage of creating a library of parts, pipeline assembly units and fastening elements, the stage of assessing the technological feasibility of manufacturing the pipeline, the stage of forming the final model of the pipeline.

The disadvantage of the above-described design is the repeated refinement of the engine layout based on the results of pipeline route analysis, which significantly increases the labor intensity of the engine manufacturing process.

The technical result to which the invention is aimed is to reduce the length of the pipeline route of a gas turbine engine by minimizing bypass zones, which makes it possible to simplify the configuration of pipelines due to an increase in straight sections and a decrease in bending radii without changing the engine design.

The technical result is achieved by the fact that the method of manufacturing a pipeline of complex configuration for a gas turbine engine using the additive method includes the creation of a three-dimensional model of the pipeline based on initial data, containing the stage of laying the pipeline route taking into account bypass zones, the stage of creating a library of parts, pipeline assembly units and fastening elements, the evaluation stage technological feasibility of pipeline manufacturing, stage of formation of the final pipeline model.

What is new in the claimed invention is that at the stage of laying the pipeline route, taking into account the bypass zones, they include determining the minimum gap between the engine and the object of application along a pre-built minimum trajectory between the starting and ending points of the pipeline route, creating a contour of the pipeline flow sections, and conducting a preliminary tracing of the pipeline contour by connecting reference points of the outer contour of the pipeline sections, ensuring a minimum gap between the pipeline route and the object of application, and ensuring a minimum gap between the pipeline route and the engine, taking into account the preliminary hydraulic calculation of the pipeline, based on the ratio:

ΔР _tk < ΔР _tk.add .,

where ΔР _tk - actual pressure loss,

ΔР _tk.add - permissible pressure loss in the line,

in this case, the geometry of the pipeline is profiled along the contour of the installation site, the thickness of the pipe wall is determined, then the pipeline is calculated for strength at various points, a central stiffener is designed at the junction of the pipeline, and the final version of the pipeline routing is included in the stage of forming the final pipeline model, taking into account the three-dimensional hydraulic calculation, then, in accordance with the created three-dimensional model, parts of the pipeline route are manufactured using the additive method, followed by their assembly.

The production of a profiled pipeline using modern additive technologies according to the contour of the installation site, ensuring strength and hydraulic losses, makes it possible to reduce the length of the pipeline route of a gas turbine engine, and therefore reduce the weight of the entire object of application.

Installing a central stiffener at the pipeline junction allows you to maintain the geometry of the pipeline during welding and obtain an even welded joint that is highly reliable.

The figures show:

fig. 1 - 3 - D model of the pipeline route;

fig. 2 - installation location of the pipeline route;

fig. 3 - part of the pipeline with a stiffener;

Fig.4 - section of the pipeline in a 3-D model;

Fig.5 - 3-D model of the pipeline;

Fig.6 - 3-D model of a pipeline designed by the method proposed by the applicant;

Fig.7 - 3-D model of the pipeline, a pipeline designed according to a standard scheme, designed by the method proposed by the applicant.

Positions in the figures are designated:

1 - pipeline (Fig. 1,2,4,5);

2 - flow part of the pipeline (Fig. 1,2,4);

3 - junction of the pipeline (Fig. 1,2)

4 - central rib (Fig. 3,4)

5 - pipeline wall (Fig. 1,3,4)

6 - contour of the pipeline section (Fig. 1,3,4)

7 - lines connecting reference points (Fig. 1)

The method is carried out as follows.

Based on the initial data of the gas turbine engine, a three-dimensional model of pipeline route 1 is formed (Fig. 1,2,4,5) with a photorealistic image using a computer-aided design (CAD) system. Such design is possible using programs such as SolidEdge, SolidWorks T-FLEX CAD 3D, KOMPAS - 3D, NX, Invertor, etc.

The optimal short trajectory of the pipeline route is preliminarily determined.

At the stage of laying the pipeline route 1 (Fig. 1,2,4,5) of the gas turbine engine, bypass zones are determined between the starting and ending points of the route. Bypass zones are understood as any structural elements that should not be crossed and/or covered by the pipeline being designed; these include: elements of the air bleed system, inspection hatch plugs, other pipelines, etc.

The main difficulty is caused by profiling the flow part 2 (Fig. 1,3,4) of pipeline 1 (Fig. 1,2,4,5), which is determined from operating conditions, as well as based on practical experience and available recommendations. The minimum gaps between the engine and the object of application are determined along a pre-constructed minimum trajectory between the starting and ending points of the pipeline route. The contours of the flow sections of the pipeline 6 are created (Fig. 1, 3, 4).

After creating the contours of the flow sections of pipeline 1 (Fig. 1,2,4,5), preliminary tracing of the contour of pipeline 1 (Fig. 1,2,4,5) is carried out by connecting the reference points of the outer contour of the sections of pipeline 1 (Fig. 1, 2,4,5) ensuring minimum clearances between the pipeline route, the object of application and the engine.

Check the provision of the required minimum gaps ΔH between pipeline route 1 (Fig. 1,2,4,5), the object of application and the gas turbine engine.

A preliminary hydraulic calculation of the main line is carried out based on the ratio:

ΔР _tk < ΔР _tk.add .,

where ΔР _tk - actual pressure loss,

ΔР _tk.add - permissible pressure loss in the line.

The pipe wall thickness in each section is preliminarily determined based on manufacturing capabilities, as well as requirements.

Where - thickness of the pipeline wall in a specific section,

k - safety factor (assigned from the current regulatory documents OST, GOST, SP, etc. or taken from the range 1<k<1000 depending on the purpose of the pipeline),

P - pressure in the pipeline,

R _eq - equivalent radius of the pipeline in a specific section,

- strength limit for a given resource (t) at a given temperature (T).

The equivalent radius of the pipeline (R _eq ) is found by the formula:

Where - area of a specific pipeline section.

In this case, for simplification, but not necessarily, it is allowed to construct the pipeline with a constant wall thickness determined by the maximum design thickness.

Pipeline 1 (Fig. 1,2,4,5) is calculated for strength at various points. If necessary, the pipeline design can provide a central rib 4 (Fig. 3,4) at the junction of pipeline 1 (Fig. 1,2,4,5). It ensures that the cross-sectional shape of the pipeline is maintained when connecting its various sections. The central rib 4 (Fig. 3,4) can be located in any part of the pipeline 1 (Fig. 1,2,4,5) and have any geometric shape. This design increases the rigidity of pipeline 1 (Fig. 1,2,4,5), which helps to distribute and reduce the pressure load on pipeline 1 (Fig. 1,2,4,5) and, as a result, reduce the likelihood of its deformation.

Proceed to the stage of creating a library of parts, assembly units of pipeline 1 (Fig. 1,2,4,5) and fastening elements, including at the junction of pipeline 3 (Fig. 1,2) and the gas turbine engine.

At the stage of assessing the technological feasibility of manufacturing pipeline 1 (Fig. 1,2,4,5), the most suitable additive manufacturing method and the number of pipeline parts are determined.

At the final stage of forming the final model of pipeline 1 (Fig. 1,2,4,5), the final version of the pipeline 1 routing (Fig. 1,2,4,5) is carried out, taking into account three-dimensional hydraulic and strength calculations, and the locations for marking are determined pipeline 1 (Fig. 1,2,4,5).

In accordance with the created three-dimensional model, parts of the pipeline route 1 (Fig. 1,2,4,5) are manufactured using the additive method and then assembled.

In the manufacture of pipeline 1 (Fig. 1,2,4,5), the following additive manufacturing methods can be used, but not excluding them:

direct metal laser sintering (DMLS);

electron beam melting (EBM);

selective laser melting (SLM);

selective sintering of powder components (SHS);

selective laser sintering of powder components (SLS).

An example of the method implementation.

For the gas turbine engine, three-dimensional models were designed and two routes of pipeline 1 were made (Fig. 1,2,3) with subsequent tests using the proposed method and the standard one.

The initial data and obtained parameters are presented in the table.

Figure 6 shows a pipeline designed by the method proposed by the applicant.

Figure 7 shows a pipeline designed according to a standard layout.

Table - initial data and obtained parameters of three-dimensional models. Pipeline designed using the proposed method Pipeline designed according to a standard scheme Initial data: Engine length: 3.4 m.
Maximum working fluid temperature: 60° C. Pipe length: 1.6 meters 2.6 meters Total pressure loss: 1.39% 5.48% Pipeline weight: 2.74 kg 3.51 kg

As a result, according to the results of the tests, a pipeline manufactured according to a standard design has a higher mass, length and total pressure loss at the outlet.

Thus, the claimed invention method for manufacturing a pipeline of a complex configuration for a gas turbine engine using the additive method can significantly reduce the length of the pipeline route by minimizing bypass zones, which allows simplifying the configuration of pipelines due to an increase in straight sections and a decrease in bending radii without changing the engine design.

Claims (5)

A method for manufacturing a pipeline of complex configuration for a gas turbine engine using an additive method, including the creation of a three-dimensional model of the pipeline based on initial data, containing the stage of laying the pipeline route taking into account bypass zones, the stage of creating a library of parts, pipeline assembly units and fastening elements, the stage of assessing the technological feasibility of manufacturing the pipeline, the stage of forming the final model of the pipeline, characterized in that the stage of laying the pipeline route, taking into account bypass zones, includes determining the minimum gap between the engine and the object of application along a pre-built minimum trajectory between the starting and ending points of the pipeline route, creating contours of pipeline flow sections, and conducting preliminary tracing of the contour pipeline by connecting reference points of the outer contour of the pipeline sections ensuring minimum gaps between the pipeline route and the object of application or engine, taking into account the preliminary hydraulic calculation of the pipeline based on the ratio: ΔР _tk. < ΔР _tk.add ., where ΔР _tk. – actual pressure loss, ΔР _tk.add – permissible pressure loss in the line, in this case, the geometry of the pipeline is profiled along the contour of the installation site, the thickness of the pipe wall is determined, then the pipeline is calculated for strength at various points, a central stiffener is designed at the junction of the pipeline, the stage of forming the final model of the pipeline includes the final version of the pipeline routing, taking into account three-dimensional hydraulic calculations, then, in accordance with the created three-dimensional model, parts of the pipeline route are manufactured using the additive method, followed by their assembly.