Bladed disk

• US 10,641,112 B2
• Filed: 08/27/2018
• Issued: 05/05/2020
• Est. Priority Date: 10/06/2017
• Status: Active Grant

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Chung, Jae-Hoon, Hillel, Malcolm L.
• Primary Examiner(s): Nguyen, Ninh H.
• Application Number:
  US16/112,940
• Publication Number:
  US 20190106997A1
• Time in Patent Office: 617 Days
• CPC Class Codes: B23P 15/02 turbine or like blades from one piece
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F01D 5/284 Selection of ceramic materials
• CPC Class Codes: F01D 5/34 Rotor-blade aggregates of unitary construction , e.g. formed of sheet laminae; discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282
• CPC Class Codes: F04D 29/321 for axial flow compressors
• CPC Class Codes: F04D 29/666 by means of rotor construction or layout, e.g. unequal distribution of blades or vanes
• CPC Class Codes: F05D 2240/30 Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
• CPC Class Codes: F05D 2260/941 particularly aimed at mechanical or thermal stress reduction
• CPC Class Codes: F05D 2260/961 by mistuning rotor blades or stator vanes with irregular interblade spacing, airfoil shape
• CPC Class Codes: F05D 2300/6032 Metal matrix composites [MMC]
• CPC Class Codes: F05D 2300/6033 Ceramic matrix composites [CMC]
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

A bladed disk may be arranged to rotate about an axis of rotation and including a rotor disk having an axial length extending from a first end to a second end, along the axis of rotation and a radial thickness extending between a first radius from the axis of rotation and a second radius from the axis of rotation, less than the first radius. The bladed disk may include a plurality of blades formed integrally with the rotor disk and arranged circumferentially around the rotor disk, and a first set of divides and a second set of divides, each divide comprising a partial break in the rotor disk extending axially from the first end of the rotor disk to the second end of the rotor disk and radially from the first radius to a third radius, less than the first radius and greater than the second radius.

Claims

1. A bladed disk arranged to rotate about an axis of rotation and including:

a rotor disk having an axial length extending from a first end to a second end, along the axis of rotation and a radial thickness extending between a first radius from the axis of rotation and a second radius from the axis of rotation, less than the first radius;

a plurality of blades formed integrally with the rotor disk and arranged circumferentially around the rotor disk; and

a first set of divides and a second set of divides, each divide comprising a partial break in the rotor disk extending axially from the first end of the rotor disk to the second end of the rotor disk and radially from the first radius to a third radius, less than the first radius and greater than the second radius, the divides arranged such that a partial break is provided in the rotor disk between each of the blades,

wherein the divides of the first set are different to the divides of the second set, and wherein the first set of divides and second set of divides are arranged in sequence circumferentially around the axis of rotation, such that the divides on either side of each blade are different.

2. The bladed disk of claim 1, comprising one or more further set of divides, each divide comprising a partial break in the rotor disk extending axially from the first end of the rotor disk to the second end of the rotor disk and radially from the first radius to a third radius, less than the first radius and greater than the second radius,

wherein the divides are arranged such that a partial break is provided in the rotor disk between each of the blades, wherein the divides of each set of divides are different, and wherein the sets of divides are arranged in sequence circumferentially around the axis of rotation, such that the divides on either side of each blade are different.

3. The bladed disk of claim 1, wherein the rotor disk comprises a foundation portion at the first radius that supports the plurality of blades;

wherein each divide comprises a first radial portion and a second radial portion;

wherein the first radial portion determines the stiffness of the adjacent foundation portions, and wherein the second radial portion isolates the foundation portion associated with circumferentially adjacent blades.

4. The bladed disk of claim 3, wherein the first radial portion of each of the first set of divides has different size and/or shape to the first radial portion of each of the second set of divides, such that stiffness of the foundation portion varies circumferentially around the rotor disk.

5. The bladed disk of claim 3, wherein the first radial portion of each divide is provided at the third radius, and the second radial portion of each divide extends from the first radius to the first radial portion.

6. The bladed disk of claim 3, wherein the first radial portion of each divide comprises a through-hole extending from the first end of the rotor disk to the second end of the rotor disk, and the second radial portion of each divide comprises a slot extending from the first radius to the through-hole.

7. The bladed disk of claim 6, wherein, in a cross section perpendicular to the axis of rotation, each through-hole has a shape and size, wherein the through-holes in the same set have the same shape and/or size, and wherein through-holes of different sets have different shape and/or size.

8. The bladed disk of claim 1, including a filler material provided in at least part of each divide.

9. The bladed disk of claim 8, wherein the filler material comprises a resiliently deformable material.

10. The bladed disk of claim 1, wherein the first radius defines an outer surface of the rotor disk, wherein each blade comprises a hub where the blade joins the rotor disk, wherein the hub of each blade follows a curved path along the outer surface of the rotor disk, and wherein each divide extends parallel to the blade hubs.

11. The bladed disk of claim 1, wherein the blisk is formed of a meta matrix composite material.

12. A turbine engine or boundary layer ingestion propulsion system comprising one or more bladed disk according to claim 1.

13. A method of manufacturing a bladed disk, the method including:

constructing, as a single integral component, a rotor disk and a plurality of blades arranged circumferentially around the rotor disk, the rotor disk having an axial length extending from a first end to a second end, along an axis of rotation of the bladed disk and a radial thickness extending between a first radius from the axis of rotation and a second radius from the axis of rotation, less than the first radius;

forming a first set of divides and a second set of divides, each divide comprising a partial break in the rotor disk extending axially from the first end of the rotor disk to the second end of the rotor disk and radially from the first radius to a third radius, less than the first radius and greater than the second radius, the divides arranged such that a partial break is provided in the rotor disk between each of the blades,

wherein the divides of the first set are different to the divides of the second set, and wherein the first set of divides and second set of divides are arranged in sequence circumferentially around the axis of rotation, such that the divides on either side of each blade are different.

14. The method of claim 13, including forming one or more further set of divides, each divide comprising a partial break in the rotor disk extending axially from the first end of the rotor disk to the second end of the rotor disk and radially from the first radius to a third radius, less than the first radius and greater than the second radius,

wherein the divides are arranged such that a partial break is provided in the rotor disk between each of the blades, wherein the divides of each set of divides are different, and wherein sets of divides are arranged in sequence circumferentially around the axis of rotation, such that the divides on either side of each blade are different.

15. The method of claim 13, wherein forming each divide comprises:

boring, at the third radius, a through-hole extending from the first end of the rotor disk to the second end of the rotor disk; and

cutting a slot extending from the first radius to the through-hole, along the axial length from the first end of the rotor disk to the second end of the rotor disk.

16. The method of claim 15, including:

boring the through-holes of each divide in a set with the same shape and/or size; and

boring the through-holes of different sets with different shape and/or size.

17. The method of claim 13, including filling at least part of each divide with a filler material.

18. The method of claim 17, wherein the filler material comprises a resiliently deformable material.

19. The method of claim 13, wherein the bladed disk is formed of a meta matrix composite material.

20. A method of claim 13, including incorporating the bladed disk into a turbine engine or boundary layer propulsion system.