US3793865A - Mixer fabrication - Google Patents

Mixer fabrication Download PDF

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Publication number
US3793865A
US3793865A US00269017A US3793865DA US3793865A US 3793865 A US3793865 A US 3793865A US 00269017 A US00269017 A US 00269017A US 3793865D A US3793865D A US 3793865DA US 3793865 A US3793865 A US 3793865A
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United States
Prior art keywords
wall
panel
bending
walls
waves
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Expired - Lifetime
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US00269017A
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English (en)
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R Krabacher
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General Electric Co
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General Electric Co
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Publication date
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • B29C53/06—Forming folding lines by pressing or scoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/08—Bending by altering the thickness of part of the cross-section of the work
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02K—JET-PROPULSION PLANTS
    • F02K1/00—Plants characterised by the form or arrangement of the jet pipe or nozzle; Jet pipes or nozzles peculiar thereto
    • F02K1/38—Introducing air inside the jet
    • F02K1/386—Introducing air inside the jet mixing devices in the jet pipe, e.g. for mixing primary and secondary flow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
    • B29C37/0057—Moulding single grooves or ribs, e.g. tear lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2024/00—Articles with hollow walls
    • B29L2024/006—Articles with hollow walls multi-channelled

Definitions

  • a turbofan mixer is fabricated from a structural panel of the variety including substantially planar first and second walls and a filler material sandwiched therebetween.
  • the mixer includes at least one acute angle formed by bending the structural panel about a portion of the first wall, whereby the first wall forms the interior and the second wall forms the exterior of the angle.
  • the first and second walls are protected from crushing and stretching proximate the apex of the angle during the bending process by the prior or contemporaneous deformation of the aforementioned portion of the first wall into a form having a plurality of repetitive waves in the cross section thereof, whereby the first wall is reduced in length relative to the smooth outer wall.
  • the first wall may be deformed by contact with a toothed roller or a reciprocable die or by other appropriate means.
  • turbofan engine In order to increase the effective thrust of the common turbojet engine, bladed fans have been added to a turbine driven shaft thereof to effect the flow of a quantity of atmospheric air through an annular passage defined between the turbojet and a radially spaced casing added thereto.
  • the turbofan engine as this combination has come to be knowm, has been found to be more efficient if the hot gas stream from the core engine (the basic turbojet portion of the turbofan) and the fan stream (the air stream forced through the annular passage by the fan) are mixed together before expulsion through a single nozzle.
  • mixers In order to perform the mixing function, mixers have been devised which include chutes formed in the shape of lobes of structural material.
  • the lobes disposed downstream of the rear or exhaust of the core engine, extend radially outward from the central circular area of the hot gas stream and into the annular passage defining the fan stream.
  • the mixer entrance is arranged so that adjacent chutes carry hot gas and fan streams respectively. Consequently, the radially separate streams entering the mixer are redirected thereby such that at the exit of the mixer the streams have been subdivided into a plurality of adjacent sectors. From this condition, the streams are mixed downstream of the mixer and exit from the engine via a single nozzle.
  • Prior attempts to accomplish such bending have often resulted in undesired damage to the panel.
  • One unsuccessful method has been to attempt to wrap the first or inner panel wall about a mold in the desired shape. This method has often led to tensile cracking of the second or outer wall during bending.
  • Another method has been to apply bending force to the outer wall; but this has led to inner wall failure through buckling under the resulting compression.
  • Other methods have led to the crushing of the core material, which reduces its strength and sound suppressing capabilities.
  • the present invention solves the bending problem by effectively shortening the length of the first or inner panel wall in the area of the apex of the desired angle, while maintaining the second or outer wall at its smooth original length so that the natural tendency of the panel is to bend around the shortened first wall.
  • This combination of operations facilitates the formation of the desired acute angle in the structural panel without the requirement to overly stress or strain either the outer or inner wall.
  • the present invention provides for the deformation of the first of two substantially planar walls of a sandwich-type structural panel over an area proximate the apex of a desired angle, and for the contemporaneous or subsequent bending of the panel to form this angle.
  • the deformation in one embodiment of the present invention, forms the first panel wall into a shape having a plurality of repetitive waves in its cross section; but any low stress deformation of the first wall which results in its being shorter than the second wall will suffice.
  • the deformation of the first panel wall may be accomplished by passing the panel between opposed rollers, one a toothed roller, for the application of transverse pressure to the panel thickness and the impression upon the first panel wall of the shape of the teeth of the toothed roller.
  • any appropriate means may be utilized for the deforming of the inner wall.
  • FIG. 1 is a partial section view of a typical turbofan engine incorporating a mixer according to the present invention
  • FIG. 2 depicts a partial end view of the mixer of the engine of FIG. 1;
  • FIG. 3 is a section view of a portion of the engine of FIG. 1 looking radially inward along line 33 in FIG.
  • FIG. 4 is a plan view of one form of bending apparatus according to the present invention operating upon a sandwich-type structural panel
  • FIG. 5 shows a cylindrical toothed roller suitable for use in the embodiment of FIG. 4;
  • FIG. 6 shows a conical toothed roller suitable for alternative use in the embodiment of FIG. 4;
  • FIG. 7 is a perspective view of a portion of a sandwich-type structural panel after operation of the bending apparatus of the present invention and using the conical roller of FIG. 6;
  • FIG. 8 is a view similar to that of FIG. 7, but wherein the panel has been operated upon by the cylindrical roller of FIG. and
  • FIG. 9 is a perspective view of a second embodiment of bending apparatus according to the present invention operating upon a sandwich-type structural panel.
  • the turbofan engine 10 seen in FIG. 1, includes a core engine 12 which generates a hot gas stream for driving fan turbine 14.
  • the fan turbine 14 is connected to and drives rotor 15 of fan 16 disposed near the inlet of the engine and upstream of the exhaust 17 from the core engine.
  • the core engine 12 and fan turbine 14 are disposed within a nacelle or inner casing 18.
  • An elongated cowl or outer casing 20 defines an engine inlet 21 and, in combination with inner casing 18, defines an annular passage 22 surrounding and coaxial with core engine 12.
  • impingement of the fan turbine 14 by the hot gas stream from the core engine exhaust l7 drives fan 16.
  • the fan 16 pressurizes an air stream entering inlet 21, the radially outward portion of which passes along annular passage 22, and the radially inner portion of which enters the core engine 12.
  • the air stream is further compressed by a core engine compressor 24 to provide a highly pressurized air stream for supporting combustion of fuel in combustor 26.
  • the hot gas stream exiting combustor 26 drives a core engine turbine 28 as well as the fan turbine 14.
  • the fan stream and hot gas stream pass through a mixer 30 and are discharged from a single nozzle 32 to provide a single stream of thrust producing exiting fluid.
  • FIG. 2 depicts an end view of the mixer 30 housed within the outer casing 20 and cooperating with the inner casing 18.
  • the mixer 30 includes a plurality of lobes 33 which project from the central circular area of the hot gas stream into the annular fan stream passage 22.
  • the lobes form alternating chutes 34 and 36 through which portions of the hot gas stream and the fan stream respectively pass to be mixed downstream of the lobes 33.
  • Each hot gas stream chute 34 is defined by an inner wall 38, an outer wall 40, and side walls 42 and 44 of lobes 33.
  • the upstream ends of adjacent walls 42 and 44 are joined at junction 43 in order to divide the hot gas stream flow as it exits the fan turbine 14 and to redirect it to enter the chutes 34 adjacent to fan stream chutes 36.
  • This junction 43 (see FIGS. 1 and 3) is formed by bending the single structural panel, from which the two walls 42 and 44 are formed, into an acute angle of small bending radius (i.e., the radius of the bend at the apex of the angle) as will be described hereinafter.
  • the fan stream chutes 36 are defined by the outer housing 20, the inner housing 18 between the lobes 33, and by the outer wall 40 and the side walls 42 and 44 of lobes 33.
  • mixers of the present variety have taught that for maximum strength, the mixer should be formed of a single piece of structural material with lobes 33 and other curved mixer portions being formed by bending the material. Additionally, interest in minimizing the noise associated with turbofan engines has dictated that mixers be formed of porous or honey comb-type material capable of absorbing sound generated by the core engine. Designs incorporating these concurrent considerations have led to the fabrication of mixers from a single sheet of sandwich-type structural panel. Such panel is commonly of the well-known variety having first and second substantially planar walls and a sound absorbent filler material sandwiched therebetween. This type of panel has proven very effective for the combined purposes for which it is used, but has presented problems of fabrication due to the inherent resistance of sandwich-type material to bending.
  • the present invention solves the problem by means of providing for the shortening of the wall of the panel used to form the interior of the desired acute angle. Moreover, this shortening is accomplished without applying excessive stress or strain to either wall. Instead, the present invention provides for the deforming of a predetermined portion of the inner wall into a shape having a plurality of repetitive waves in the cross section thereof. The overall effect is to shorten the total length of the deformed wall relative to the still smooth second wall in order to make use of the natural tendency of the panel to bow or bend around the nowshortened deformed wall portion to facilitate the formation of the desired angle at that point.
  • FIG. 4 illustrates a first apparatus for accomplishing the bending according to the present invention.
  • a structural panel 50 having first and second substantially planar walls 52 and 54 sandwiching filler material 56 is shown being fed into the bending apparatus of this first embodiment.
  • a plurality of rollers 60 are spaced from an opposed toothed roller 62 which carries a number of teeth 64 of predetermined shape and size along its circumference. The number, size, and spacing of the teeth 64 are determined in accordance with the size and bending radius R of the angle desired to be formed.
  • the application of pressure transverse the panel 50 by rollers 60 and 62 serves to deform a predetermined portion of panel 50 into a form having a plurality of waves W having repetitive pitch, shape and size in the cross section.
  • wall 52 is shortened in total length with respect to wall 54, although the surface lengths of the two walls remain substantially the same.
  • the effect of the shortening of wall 52 is to bow the panel in the direction shown in FIG. 4, and the bending of the panel further in this direction is thus facilitated. It will be apparent to one skilled in the art that the deformation of wall 52 in the manner shown by the application of pressure transverse its surface does not tend to strain the material of the wall as significantly as the stretching or crushing of the wall in the described bending methods of the prior art.
  • junction 43 of walls 42 and 44 of FIG. 3 may be formed.
  • the apex of the angle of the junction between these two walls must be of relatively small radius R. This is required in order to efficiently divide the hot gas flow without losing excessive amounts of the kinetic energy thereof to stagnation.
  • Application of this inventions bending technique to the panel forming walls 42 and 44 in FIG. 3 is evidenced by the waves W appearing upon the inner surface of junction 43 at the apex of the angle formed there.
  • the method of the present invention is particularly suited. However, it is to be noted that this process might be utilized in any bending of such a panel. Larger radius bends and thicker panel cross sections would permit the use of a toothed roller 62 in FIG. 4 having larger pitch between teeth 64 as well as greater tooth depth. Thus, the present invention is readily adaptable to uses involving different bending radii.
  • Another end achieved by the present invention is the provision for choice between uniform and non-uniform bending radii within a single structure.
  • it may be desired to form an angle having an apex of uniform bending radius similar to that depicted in FIG. 8, or one of graduated bending radius similar to that shown in FIG. 7.
  • a graduated bending radius R to R would be appropriate.
  • R a uniform bending radius
  • the walls 42 and 44 of mixer 30 in FIGS. 1 and 3 are preferably aligned in a constant angle along the length of material between radially inner and outer points 43a and 43b of junction 43 (see FIG. 1).
  • an angle having an apex with a uniform bending radius is suitable.
  • FIGS. 5 and 6 depict alternative embodiments of the toothed rollers 62 of FIG. 4, suitable respectively for forming uniform and graduated bending radii.
  • the roller 62 is cylindrical and is adapted to bend a predetermined portion of panel into a form wherein the repetitive waves making up the deformed portion of the panel are substantially parallel across the panel width and thus the angle formed will have a uniform radius of bending along the apex of the angle.
  • parallel lines 53 represent the waves created by the impression upon wall 52 of adjacent teeth of cylindrical roller 62.
  • a conical or tapered toothed roller 62" as shown in FIG. 6 will produce non-parallel wave impressions when applied to wall 52 of panel 50 owing to the teeth of the roller.
  • non-parallel lines 53' represent the waves created by the impression ofthe teeth of conical toothed roller 62" of FIG. 6.
  • the angle formed in the panel will have an apex having a larger radius of bending at one end of the panel width than at the other.
  • FIG. 9 An alternative embodiment of the present invention is depicted in FIG. 9 wherein the toothed roller is replaced by a reciprocable die 70, and the smooth opposed rollers 60 are replaced by a supporting or bearing wall 72.
  • the apparatus in FIG. 9 is shown operating upon the same sandwich-type structural panel 50 having first wall 52, second wall 54, and filler 56.
  • a predetermined portion of wall 50 is gradually fed between supporting wall 72 and opposed die 70.
  • Pressure is applied transverse the advancing panel 50, and reciprocable die deforms wall 52 into a plurality of repetitive waves in the cross section.
  • the pitch between adjacent waves as well as wave depth are determined by the bending radius R to be achieved as well as by the thickness of panel 50.
  • the deformation of wall 52 by the impression thereupon of die 70 will create a tendency in panel 50 to bow and will facilitate the bending of the panel about the deformed portion thereof. In this manner, the fabrication of an angle in sandwich-type structural panels is achieved by the application of the present invention in this second embodiment.
  • the application of the principles of the present invention are not limited to use in fabricating mixers for turbofan engines. Nor are they limited to applications wherein sandwich-type structural panels are desired to be bent into acute angles having small radii of bending. Furthermore, while the means by which the bending is accomplished have been described with reference to two embodiments, one skilled in the art will be easily able to devise variations of these embodiments. For example, a plurality of dies might bear against and deform a panel simultaneously into the desired formation thereof. Other variations may be devised without departing from the spirit of the present invention.
  • a method for forming an angle in structural panels of the variety including substantially planar first and second walls and a filler material sandwiched between the first and second walls, said method comprising the steps of:
  • a method for forming an angle in structural panels of the variety including substantially planar first and second walls and a filler material sandwiched between the first and second walls, said method comprising the steps of:
  • said toothed roller is substantially cylindrical in configuration, and said plurality of waves formed in said first wall are substantially parallel to one another.
  • said toothed roller is substantially conical in configuration, and said plurality of waves formed in said first wall are substantially non-parallel with one another.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
US00269017A 1972-07-05 1972-07-05 Mixer fabrication Expired - Lifetime US3793865A (en)

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US26901772A 1972-07-05 1972-07-05

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US00269017A Expired - Lifetime US3793865A (en) 1972-07-05 1972-07-05 Mixer fabrication

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US (1) US3793865A (it)
JP (1) JPS4944108A (it)
BE (1) BE801970A (it)
CA (1) CA989290A (it)
DE (1) DE2333917A1 (it)
FR (1) FR2196902B1 (it)
GB (1) GB1431668A (it)
IT (1) IT990931B (it)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4481698A (en) * 1982-06-01 1984-11-13 Salerno Alan F Chuted mixer forming method
FR2842443A1 (fr) * 2002-07-19 2004-01-23 Alfred Chocroun Plaque metallique, son procede de fabrication et son procede de pliage
US20100229618A1 (en) * 2008-12-18 2010-09-16 Eugene Gekht Method and apparatus for forming a turbofan mixer
CN108119261A (zh) * 2017-12-22 2018-06-05 湖南省力宇燃气动力有限公司 混合器及燃气发动机
CN111250577A (zh) * 2020-03-20 2020-06-09 广州大峰精密工业有限公司 一种用于汽车涡轮节能混合器生产的卷圆机
US20200254698A1 (en) * 2017-10-03 2020-08-13 Safran Ceramics Production in composite material of a lobed structure of a flow mixer

Families Citing this family (10)

* Cited by examiner, † Cited by third party
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US4045957A (en) * 1976-02-20 1977-09-06 United Technologies Corporation Combined guide vane and mixer for a gas turbine engine
GB2082259B (en) * 1980-08-15 1984-03-07 Rolls Royce Exhaust flow mixers and nozzles
GB2123486B (en) * 1982-07-12 1986-01-02 Gen Electric Turbofan mixed flow exhaust system
GB2197810B (en) * 1986-09-22 1990-10-03 Jackson Paul Adrian Southon Sheet metal articles
JPS6436077U (it) * 1987-08-28 1989-03-06
DE3831363A1 (de) * 1988-09-15 1990-03-29 Erbsloeh Julius & August Verfahren zum biegen von sandwichplatten
NL8902899A (nl) * 1989-11-23 1991-06-17 Schreiner Luchtvaart Werkwijze voor het vervaardigen van een voorwerp uit een thermoplastisch sandwichmateriaal.
DE102006027506B4 (de) * 2006-06-14 2010-06-10 Mtu Aero Engines Gmbh Gasturbinengehäuse und Verfahren zur Herstellung eines Gasturbinengehäuses
DE102009011452A1 (de) * 2009-03-03 2010-09-09 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung eines Ejektor-Düsen-Rohrs
CN114012875B (zh) * 2021-11-24 2022-11-15 西北工业大学 一种陶瓷基复合材料混合器的预制体定型模具及使用方法

Citations (5)

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US1978240A (en) * 1931-01-19 1934-10-23 Harley T Wheeler Making of packing rings
US2047001A (en) * 1932-12-10 1936-07-07 Preston Davie Apparatus for making foraminous elements
US2604984A (en) * 1949-03-18 1952-07-29 Seaboard Container Corp Fan-folded stack of corrugated board for tubular containers
FR1260187A (fr) * 1960-03-25 1961-05-05 Renault Procédé pour l'obtention d'éléments profilés à partir de panneaux composés plans et éléments profilés obtenus par ce procédé
US3664170A (en) * 1970-03-16 1972-05-23 Pacific Roller Die Co Inc Curving method and apparatus for ridged sheet material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1978240A (en) * 1931-01-19 1934-10-23 Harley T Wheeler Making of packing rings
US2047001A (en) * 1932-12-10 1936-07-07 Preston Davie Apparatus for making foraminous elements
US2604984A (en) * 1949-03-18 1952-07-29 Seaboard Container Corp Fan-folded stack of corrugated board for tubular containers
FR1260187A (fr) * 1960-03-25 1961-05-05 Renault Procédé pour l'obtention d'éléments profilés à partir de panneaux composés plans et éléments profilés obtenus par ce procédé
US3664170A (en) * 1970-03-16 1972-05-23 Pacific Roller Die Co Inc Curving method and apparatus for ridged sheet material

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4481698A (en) * 1982-06-01 1984-11-13 Salerno Alan F Chuted mixer forming method
FR2842443A1 (fr) * 2002-07-19 2004-01-23 Alfred Chocroun Plaque metallique, son procede de fabrication et son procede de pliage
WO2004009262A1 (fr) * 2002-07-19 2004-01-29 Arcelor Steel Service Centres Plaque metallique, son procede de fabrication et son procede de pliage
US20060147732A1 (en) * 2002-07-19 2006-07-06 Alfred Chocroun Metal plate, method for making same and method for folding same
US20100229618A1 (en) * 2008-12-18 2010-09-16 Eugene Gekht Method and apparatus for forming a turbofan mixer
US9616484B2 (en) 2008-12-18 2017-04-11 Pratt & Whitney Canada Corp. Method and apparatus for forming a turbofan mixer
US20200254698A1 (en) * 2017-10-03 2020-08-13 Safran Ceramics Production in composite material of a lobed structure of a flow mixer
US11667089B2 (en) * 2017-10-03 2023-06-06 Safran Ceramics Production in composite material of a lobed structure of a flow mixer
CN108119261A (zh) * 2017-12-22 2018-06-05 湖南省力宇燃气动力有限公司 混合器及燃气发动机
CN108119261B (zh) * 2017-12-22 2024-06-04 湖南省力宇燃气动力有限公司 混合器及燃气发动机
CN111250577A (zh) * 2020-03-20 2020-06-09 广州大峰精密工业有限公司 一种用于汽车涡轮节能混合器生产的卷圆机

Also Published As

Publication number Publication date
BE801970A (fr) 1973-11-05
IT990931B (it) 1975-07-10
JPS4944108A (it) 1974-04-25
GB1431668A (en) 1976-04-14
FR2196902A1 (it) 1974-03-22
FR2196902B1 (it) 1974-07-05
CA989290A (en) 1976-05-18
DE2333917A1 (de) 1974-01-17

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