Assessing the potential benefits of manufacturing gas turbine components by utilizing hydroforming technology

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

Abstract

Hydroforming, which utilizes hydraulic pressure to manufacture metallic components, is a near net shape forming process that could offer many potential advantages in terms of cost, mechanical properties, weight reduction and manufacturing time over traditional production methods. Through the use of two case studies with components similar to ones used in gas turbine engines, this paper presents different ways in which hydroforming technology could be exploited to reduce both the part count and operations required to manufacture certain aerospace structures by using methods which have already shown to be effective in other industries. It is shown that cost, manufacturing operations and manufacturing complexity can be reduced while maintaining the function of a component by switching the manufacturing process from a conventional method to one that includes hydroforming. These parts illustrate a method for assessing hydroforming manufacturability from reported theory and heuristics in the available literature. The results provide an example which engineers can use as a case study for how to start assessing how easily a given component can be adapted to the hydroforming process and how the benefits can be assessed.

The reason for these results is that hydroforming offers a greater level of material formability compared to other forming processes and as individual components become geometrically more complicated the overall part count can be reduced as it takes fewer components to make an assembly, which in turn reduces weight as fewer nuts, bolts, seals and welding flanges are needed. The automotive industry has already demonstrated that this approach can deliver tangible benefits and hydroformed components are already used in larger airframe structures, but the hope is that the same approach can facilitate similar weight and cost savings in gas turbine engine components.

Conference

Conference13th International Cold Forming Congress
CountryUnited Kingdom
CityGlasgow
Period2/09/154/09/15
Internet address

Fingerprint

Turbine components
Gas turbines
Turbines
Nuts (fasteners)
Costs
Airframes
Bolts
Formability
Flanges
Automotive industry
Seals
Welding
Hydraulics
Engineers
Mechanical properties
Industry

Keywords

  • gas turbine manufacturing
  • cold forming
  • hydroforming

Cite this

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title = "Assessing the potential benefits of manufacturing gas turbine components by utilizing hydroforming technology",
abstract = "Hydroforming, which utilizes hydraulic pressure to manufacture metallic components, is a near net shape forming process that could offer many potential advantages in terms of cost, mechanical properties, weight reduction and manufacturing time over traditional production methods. Through the use of two case studies with components similar to ones used in gas turbine engines, this paper presents different ways in which hydroforming technology could be exploited to reduce both the part count and operations required to manufacture certain aerospace structures by using methods which have already shown to be effective in other industries. It is shown that cost, manufacturing operations and manufacturing complexity can be reduced while maintaining the function of a component by switching the manufacturing process from a conventional method to one that includes hydroforming. These parts illustrate a method for assessing hydroforming manufacturability from reported theory and heuristics in the available literature. The results provide an example which engineers can use as a case study for how to start assessing how easily a given component can be adapted to the hydroforming process and how the benefits can be assessed.The reason for these results is that hydroforming offers a greater level of material formability compared to other forming processes and as individual components become geometrically more complicated the overall part count can be reduced as it takes fewer components to make an assembly, which in turn reduces weight as fewer nuts, bolts, seals and welding flanges are needed. The automotive industry has already demonstrated that this approach can deliver tangible benefits and hydroformed components are already used in larger airframe structures, but the hope is that the same approach can facilitate similar weight and cost savings in gas turbine engine components.",
keywords = "gas turbine manufacturing, cold forming, hydroforming",
author = "Colin Bell and Jonathan Corney and John Storr",
year = "2015",
month = "9",
day = "2",
language = "English",
isbn = "978-1-909522-12-1",
pages = "46--53",
booktitle = "13th International Cold Forming Congress",

}

Bell, C, Corney, J & Storr, J 2015, Assessing the potential benefits of manufacturing gas turbine components by utilizing hydroforming technology. in 13th International Cold Forming Congress. pp. 46-53, 13th International Cold Forming Congress, Glasgow, United Kingdom, 2/09/15.

Assessing the potential benefits of manufacturing gas turbine components by utilizing hydroforming technology. / Bell, Colin; Corney, Jonathan; Storr, John.

13th International Cold Forming Congress. 2015. p. 46-53.

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

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AU - Corney, Jonathan

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N2 - Hydroforming, which utilizes hydraulic pressure to manufacture metallic components, is a near net shape forming process that could offer many potential advantages in terms of cost, mechanical properties, weight reduction and manufacturing time over traditional production methods. Through the use of two case studies with components similar to ones used in gas turbine engines, this paper presents different ways in which hydroforming technology could be exploited to reduce both the part count and operations required to manufacture certain aerospace structures by using methods which have already shown to be effective in other industries. It is shown that cost, manufacturing operations and manufacturing complexity can be reduced while maintaining the function of a component by switching the manufacturing process from a conventional method to one that includes hydroforming. These parts illustrate a method for assessing hydroforming manufacturability from reported theory and heuristics in the available literature. The results provide an example which engineers can use as a case study for how to start assessing how easily a given component can be adapted to the hydroforming process and how the benefits can be assessed.The reason for these results is that hydroforming offers a greater level of material formability compared to other forming processes and as individual components become geometrically more complicated the overall part count can be reduced as it takes fewer components to make an assembly, which in turn reduces weight as fewer nuts, bolts, seals and welding flanges are needed. The automotive industry has already demonstrated that this approach can deliver tangible benefits and hydroformed components are already used in larger airframe structures, but the hope is that the same approach can facilitate similar weight and cost savings in gas turbine engine components.

AB - Hydroforming, which utilizes hydraulic pressure to manufacture metallic components, is a near net shape forming process that could offer many potential advantages in terms of cost, mechanical properties, weight reduction and manufacturing time over traditional production methods. Through the use of two case studies with components similar to ones used in gas turbine engines, this paper presents different ways in which hydroforming technology could be exploited to reduce both the part count and operations required to manufacture certain aerospace structures by using methods which have already shown to be effective in other industries. It is shown that cost, manufacturing operations and manufacturing complexity can be reduced while maintaining the function of a component by switching the manufacturing process from a conventional method to one that includes hydroforming. These parts illustrate a method for assessing hydroforming manufacturability from reported theory and heuristics in the available literature. The results provide an example which engineers can use as a case study for how to start assessing how easily a given component can be adapted to the hydroforming process and how the benefits can be assessed.The reason for these results is that hydroforming offers a greater level of material formability compared to other forming processes and as individual components become geometrically more complicated the overall part count can be reduced as it takes fewer components to make an assembly, which in turn reduces weight as fewer nuts, bolts, seals and welding flanges are needed. The automotive industry has already demonstrated that this approach can deliver tangible benefits and hydroformed components are already used in larger airframe structures, but the hope is that the same approach can facilitate similar weight and cost savings in gas turbine engine components.

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