The invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 shows a perspective view of a known casing (PRIOR ART);
FIG. 2 shows a plan view of a sheet metal blank according to the present invention;
FIG. 3 shows a perspective view of a casing according to the present invention;
FIG. 4 shows a known rolling arrangement for bending the blank of the present invention;
FIG. 5 shows the casing in position on a sizing tool; and
FIG. 6 shows a plan view of an alternative embodiment of a sheet metal blank according to the present invention.
Presented in FIG. 1 (PRIOR ART) is a perspective view of a known casing 10. The casing 10 is frusto conical and may form an outer casing for a compressor or turbine module (not shown). The casing 10 is defined by a wall 12 which has a substantially constant thickness. The wall 12 is provided with a number of bosses 14 over its outer surface 15, the bosses 14 being raised from the surface 15 such that the overall thickness of the casing 10 where a boss 14 is present is greater than the thickness of the wall 15. Flanges 16,18 are provided at either end of the casing 10 for attachment to engine components upstream and downstream of the casing. The casing 10 may have been produced from a casting, or perhaps a forging where the bosses 14 and flanges 16, 18 have been machined to their final dimensions. Alternatively it may have been produced from a plain sheet metal casing with bosses 14 welded into place on the surface 15.
In contrast the casing of the present invention is formed from a sheet metal blank 20 as shown in FIG. 2. The blank 20 is in the form of a sector of a ring. That is to say it has a two curved parallel sides 22, 24 and two ends 26, 28 which are at an angle to one another but which both are perpendicular to a tangent at their junction with the curved sides 22, 24 of the blank 20. The blank 20 is formed from a sheet of metal of substantially constant wall thickness, which is then machined, chemical etched, forged, pressed or otherwise formed such that the resultant blank 20 has a wall 30 of substantially constant thickness and at least one raised or thicker region 32 extending along substantially the full length of the sheet metal blank 20. In the embodiment shown flanges 34, 36 are provided along both edges of the sheet metal blank form part for the raised/thicker region 32. Further raised regions 32 are provided between edges 24, 26 of the sheet metal blank 20 in the form of bosses 38, and ridges 40, where the ridges 40 extend away from each of the bosses 38 and/or link bosses 38.
The wall 30 has a thickness greater than 0.7 mm but not greater than 5 mm, and the raised regions 32 have a thickness no greater than twice the thickness of the wall 30. The thicker regions 32 have substantially constant thickness along the full length of the blank. The bosses 38 and ridges 40 extends from one side of the wall 30 sheet metal blank, and the other side of the sheet metal blank wall 30 is planar. The sheet metal blank 20, 80 is preferably made from titanium.
As shown in FIG. 2, the bosses 38 may be linked to other bosses 38 by the ridges 40. Alternatively bosses may be provided in isolation with ridges 40 extending away from them for a distance. However, at all points along the length of the blank 20 there is at least one feature 32 which is raised above the wall surface 30.
In the region where the ridges 40 meet the bosses 38, the ridges 40 splay out so as to provide a lead in to the bosses 38. That is to say, the ridges 40 run onto the crown of the bosses 38 such that the there is a gradual change in width of the raised feature 32 in the transition between the ridge 40 and the bosses 38.
FIG. 3 shows a casing 50 formed from the sheet metal blank 20 of FIG. 2. The blank 20 is deformed such that it is substantially circular in cross-section and then joined at the ends 26, 28 to form the frusto conical casing 50. The sheet metal blank 20 is joined at ends 26, 28 by a weld 52.
The sheet metal blank 20 is deformed by a process known as rolling, as illustrated in FIG. 4, in which the blank 20 is passed along a series of rollers 60, 62, 64, the through path defined by the rollers 60, 62, 64 being wider than the thickness of the wall 30 of the sheet 20 (shown as a dotted line in FIG. 4), but narrower than the thickness of the thicker region 32. The distance between the rollers 60, 62, 64 is fixed during the rolling operation, hence the rollers 60, 62, 64 do not contact the metal blank 20 at its thinnest regions on both sides of wall 30. The raised regions 32 (that is to say, the ridges 40 extending away from and between the bosses 38 and/or the flanges 34, 36) ensure the sheet metal blank 20 is in contact with the rollers 60, 62, 64 throughout the bending process such that the sheet metal blank 20 is bent along substantially its full length to form an arcuate sheet. The arcuate sheet is then is joined at its ends 26, 28 to form a casing 50 with a substantially circular cross section.
As shown in FIG. 5 the casing 50 may then optionally be further formed by being placed on a jig 70 and stretched either expansion of the jig and/or by being forced down the conical surface of the jig 70. Such stretching enables the final dimensions of the casing 50 to achieved. That is to say, after the ends 26, 28 are joined the casing 50 may not have the desired cross section at all points along its length, and the optional stretching step will ensure the design dimensions are achieved. Some or all of the bosses 38 may then be machined to produce a flat location surface.
In an alternative embodiment, where a cylindrical rather than frusto-conical casing is required, a rectangular sheet metal blank 80, as shown in FIG. 6, may be produced rather than the arcuate blank 20 shown in FIG. 2. Other than the rectangular shape, features of the blank 80 and method of manufacture of the blank and resultant casing are common to the blank 20.
In the embodiments herein described the blank 20, 80 and casing 50 are described as having a plurality of bosses 38 and ridges 40. However, in an application where bosses are not required, only ridges and/or a flange extending along the full length of the blank 28, 80 are provided. Alternatively a blank 20, 80 may be provided with a single boss 38 and/or a single ridge 40 extending away from the boss 38.
The raised region 32 extends substantially along the full length of the sheet metal blank 20, 80. However, lead in features at the ends 26, 28 of the blank 20, 80 may be provided which have either no raised region 32, or a tapered raised region. These will help to feed the blank into to rolling/bending device.
The splayed ends of the ridges 40 in the transition region between the ridges 40 and the bosses 38 also act as a lead in for each boss 38 between the rollers (60, 62, 64), thus reducing the occurrence of an uneven residual stress in the region of the boss 38 when bent.
In the embodiment described above, the casing is manufactured from one piece of sheet metal. In an alternative embodiment, the casing is made from two or more deformed sheet metal blanks, which are then joined together to form one substantially cylindrical or frusto-conical shape.
The method of deforming the sheet metal blank such that it is substantially arcuate or circular in cross section may be achieved by use of a press brake rather than by rolling.
Reference is hereinbefore made to sheet metal, where a “sheet” is intended to described a material provided in a substantially flat and plane form. In this context “sheet metal” is exchangeable with “plate metal”, another term of the art, which is indicative of a material which is provided in a thicker form than a “sheet”.
The raised or thicker regions 32 have a width of no less than 7 mm. In a titanium alloy casing this has been shown to distribute stress around the features of the thicker region to within optimal limits.
Providing a casing with thicker/raised regions extending between bosses is counterintuitive, as it will be appreciated that ordinarily such features act a stress concentration features. It is only with careful positioning, sizing and shaping that the raised features can be “tuned” to produce a structure which is more rigid than that of the prior art (since the thicker/raised regions stiffen the casing) and which results in a component with stress concentrations that are within acceptable limits.
Patent Application
20080078227
