Exemplary embodiments of the present disclosure relate generally to gas turbine engines and, in one embodiment, to thermal zone cooling in a bearing compartment of a gas turbine engine.
In a gas turbine engine, air is compressed in a compressor and compressor air is then mixed with fuel and combusted in a combustor to produce a high-temperature and high-pressure working fluid. This working fluid is directed into a turbine in which the working fluid is expanded to generate power. The generated power drives the rotation of a rotor within the turbine through aerodynamic interactions between the working fluid and turbine blades or airfoils. The rotor can be used to drive rotation of a propeller/fan or to produce electricity in a generator.
Certain parts, such as a bearing compartment, in a gas turbine engine need a supply of oil for cooling and/or lubrication. In conventional systems, oil is supplied via tubes that are separate from other components. In tight locations, there may be limited options where tubes can be added to reach oil nozzles. This can constrain oil nozzle placement and make assembly difficult where multiple tubes must be routed around other components. Some locations may experience higher heat loads during operation as compared to other locations.
According to an aspect, a bearing compartment includes a body, one or more oil cooling channels integrally formed within the body, and one or more oil nozzles coupled to the one or more oil cooling channels. At least one of the one or more oil nozzles is oriented to direct oil toward a thermal zone with a predicted hot spot within the bearing compartment.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the at least one of the one or more oil nozzles can be integrally formed with the body of the bearing compartment.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the body can include a housing of the bearing compartment.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the body can include a spring integrally formed with the housing.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the one or more oil cooling channels can be routed through at least one annular support member of the spring.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the one or more oil cooling channels can include one or more struts of the spring.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, placement and orientation of the one or more oil nozzles can be configured based on a thermal model of a plurality of thermal zones within the bearing compartment.
According to an aspect, a gas turbine engine includes a compressor section, a turbine section, a shaft coupled to the compressor section and the turbine section, and a bearing system configured to support rotation of the shaft. The bearing system include a bearing compartment with a body, one or more oil cooling channels integrally formed within the body, and one or more oil nozzles coupled to the one or more oil cooling channels. At least one of the one or more oil nozzles is oriented to direct oil toward a thermal zone with a predicted hot spot within the bearing compartment.
According to an aspect, a method of manufacturing a bearing compartment is provided. The method includes analyzing a thermal model for thermal data associated with a plurality of thermal zones within a bearing compartment having a modeled temperature above a threshold level to identify a predicted hot spot. The method also includes modifying a design file of the bearing compartment to add one or more oil cooling channels in a body of the bearing compartment and one or more oil nozzles coupled to the one or more oil cooling channels and directed toward the predicted hot spot. The method further includes providing the design file to additive manufacturing equipment to build the body of the bearing compartment including the one or more oil cooling channels integrally formed within the body.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the method can include controlling the additive manufacturing equipment to additively manufacture the bearing compartment based on the design file.
In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the method can include where placement and orientation of the one or more oil nozzles are configured based on the thermal model and a three-dimensional structural model of the bearing compartment.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
The exemplary gas turbine engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided, and the location of bearing systems 38 may be varied as appropriate to the application.
The low speed spool 30 generally includes an inner shaft 40 that interconnects a fan 42, a low pressure compressor 44 and a low pressure turbine 46. The inner shaft 40 is connected to the fan 42 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 48 to drive the fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a high pressure compressor 52 and high pressure turbine 54. A combustor 56 is arranged in the gas turbine engine 20 between the high pressure compressor 52 and the high pressure turbine 54. The engine static structure 36 is arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The engine static structure 36 further supports the bearing systems 38 in the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
The core airflow is compressed by the low pressure compressor 44 and then the high pressure compressor 52, is mixed and burned with fuel in the combustor 56 and is then expanded over the high pressure turbine 54 and the low pressure turbine 46. The high and low pressure turbines 54 and 46 rotationally drive the low speed spool 30 and the high speed spool 32, respectively, in response to the expansion. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may be varied. For example, geared architecture 48 may be located aft of the combustor section 26 or even aft of the turbine section 28, and the fan section 22 may be positioned forward or aft of the location of geared architecture 48.
The gas turbine engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 46 has a pressure ratio that is greater than about five. In one disclosed embodiment, the gas turbine engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44, and the low pressure turbine 46 has a pressure ratio that is greater than about five 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present disclosure is applicable to other gas turbine engines including direct drive turbofans.
A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the gas turbine engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet (10,688 meters). The flight condition of 0.8 Mach and 35,000 ft (10,688 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)]0.5. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second (350.5 m/sec).
With continued reference to
The upper portion 234 of the housing 230 can include an overhang region 236 that is supported by the spring 220 during an additive manufacturing build process. For example, the bearing compartment 202 can be manufactured using a powder bed fusion process, e.g., laser or electron beam based, to progressively build the housing 230 from the lower portion 232 to the upper portion 234 while also building the spring 220 within an interior of the housing 230. Forming the spring 220 integrally with the housing 230 can enhance structural stability and prevent the spring 220 from rotating relative to the housing 230 during assembly of the bearing compartment 202.
The spring 220 can include a plurality of struts 222 that extend axially within the housing 230. The spring 220 can be a squirrel cage spring, and a centerline D of the struts 222 can extend axially in parallel to an axis of rotation (e.g., engine central longitudinal axis A) defined within a central cavity 240 of the bearing compartment 202. The struts 222 can extend between a first annular support member 224 (e.g., a lower support) and a second annular support member 226 (e.g., an upper support).
In some embodiments, the spring 220 can include one or more oil cooling channels 250 internally fabricated within one or more struts 222 of the spring 220. The oil cooling channels 250 can provide a path for oil flow through the spring 220 to deliver oil at or below the lower support 224. The oil cooling channels 250 can be fabricated within the upper support 226 and through two or more of the struts 222. The oil cooling channels 250 within the upper support 226 can form a manifold 252 to distribute oil to two or more of the struts 222. Oil can be delivered directly to an oil nozzle 260 or be routed through one or more components of the bearing compartment 202 before reaching an oil nozzle 260 after flowing through the oil cooling channels 250. In some embodiments, all of the struts 222 can include the oil cooling channels 250. Alternatively, a subset of the struts 222 can include the oil cooling channels 250, such as every other strut 222, every third strut 222, every fourth strut 222, etc. The number of struts 222 that incorporate the oil cooling channels 250 can be determined by an oil flow and pressure analysis. Incorporating the oil cooling channels 250 in two or more of the struts 222 can provide a substantially symmetrical design of the spring 220 and multiple distribution paths. The path of the oil cooling channels 250 within the housing 230 can be determined based on structural analysis and flow dynamics of the oil.
The upper support 226 can include the manifold 252 and/or the lower support 224 can include a lower manifold 262 that allows oil circulation above and/or below the struts 222 within the spring 220. As one example, oil can enter the oil cooling channels 250 at port 248 and circulate through the manifold 252, lower manifold 262, and oil cooling channels 250 within the struts 222 to reach oil nozzles 260 oriented to direct oil toward one or more thermal zones 265 with predicted hot spots 264 within the bearing compartment 202. Thermal zones 265 can be defined within regions where heat accumulates due to circulation, movement of components, transfer from external sources, and other such factors. The predicted hot spots 264 may have a locally higher temperature within a thermal zone 265 than surrounding areas during operation of the gas turbine engine 20. Although the example of
The build process of the additive manufacturing equipment 400 can be controlled by a control system 430. The control system 430 can include a processing system 432 and a memory system 434, where the memory system 434 stores executable instructions to configure the processing system 432 to perform a plurality of operations. The processing system 432 can include any type or combination of central processing unit (CPU), including one or more of: a microprocessor, a digital signal processor (DSP), a microcontroller, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or the like. The memory system 434 can store data and instructions that are executed by the processing system 432. In embodiments, the memory system 434 may include random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic, or any other computer readable medium onto which is stored data and algorithms in a non-transitory form. The control system 430 can also include an input/output (I/O) interface 436 operable to interface with various components of the additive manufacturing equipment 400 to sense, control, and communicate with components of
The additively-manufactured part 412 can be the bearing compartment 202 of
It will be understood that the additive manufacturing equipment 400 can include other components beyond those depicted in the example of
With reference to
In some embodiments, the spring 220 is additively manufactured as a squirrel cage spring, and a centerline D of the struts 222 extend axially in parallel to an axis of rotation defined within a central cavity 240 of the bearing compartment 202. In some embodiments, the spring 220 includes an annular support member, such as the first annular support member 224 and/or the second annular support member 226, and the struts 222.
In some embodiments, at least one of the one or more oil nozzles 260 can be integrally formed with the body 205 of the bearing compartment 202. The body 205 can include a housing 230 of the bearing compartment 202 and/or the body 205 can include a spring 220 integrally formed with the housing 230. The one or more oil cooling channels 250 can be routed through at least one annular support member 224, 226 of the spring 220. The one or more oil cooling channels 250 can include one or more struts 222 of the spring 220. Placement and orientation of the one or more oil nozzles 260 can be configured based on the thermal model 444 and 3-D structural model 442 of the bearing compartment 202.
With reference to
At block 602, one or more keyways can be incorporated into a design file of the bearing compartment 202 to control placement of one or more oil nozzles with respect to one or more oil cooling channels, such as oil nozzles 260 and oil cooling channels 250. At block 604, the bearing compartment 202 with the one or more keyways can be additively manufactured, for instance, using additive manufacturing equipment 400 of
With reference to
When the base 723 is tightly fit in the keyway 712 as shown in
Benefits of the features described herein include providing greater oil routing capability beyond areas that can be reached through separate tubing or through drilled paths in the components. This can be combined with additional cooling fins and other such features as part of a collective heat management approach. Using model data can also assist in confirming that the newly added internal oil paths maintain the structural integrity of the components when connected to an existing pressure head used to feed existing nozzles in the design.
The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. Terms such as “upper” and “lower” are used for purposes of explanation and the designation as such can be altered depending upon component orientation.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
This application claims the benefit of U.S. Provisional Application No. 63/423,357 filed Nov. 7, 2023, the disclosure of which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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63423357 | Nov 2022 | US |