Additive manufactured gear for a geared architecture gas turbine engine

Patent metadata

Field	Value
Publication number	US-10371244-B2
Application number	US-201514682390-A
Country	US
Kind code	B2
Filing date	Apr 9, 2015
Priority date	Apr 9, 2015
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A gear includes a multiple of gear teeth that extend from an outer portion of a rim about an axis and an inner portion of the rim about the axis, the inner portion of the rim additive manufactured.

First claim

What is claimed is:

1. A gear, comprising:
a multiple of gear teeth that extend from an outer portion of a rim about an axis;
said gear teeth subtractive manufactured from the outer portion;
and

an inner portion of said rim about said axis, said inner portion of said rim additive manufactured to the outer portion at an interface;
wherein said inner portion of said rim includes a matrix;
wherein said matrix forms a lattice structure.

2. The gear as recited in claim 1 , wherein said inner portion of said rim forms a journal bearing surface.

3. The gear as recited in claim 1 , wherein said gear is an intermediate gear of a geared architecture for a gas turbine engine, said intermediate gear is a double helical gear.

4. The gear as recited in claim 1 , wherein said inner portion provides different characteristics along an axial length.

5. The gear as recited in claim 1 , wherein said interface is a bond layer that facilitates receipt of a dissimilar material that is applied to said outer portion of said rim via an additive manufacturing process.

6. The gear as recited in claim 1 , wherein said interface is mechanical interlock.

7. A geared architecture for a gas turbine engine, said geared architecture, comprising:
a sun gear;
a ring gear that surrounds said sun gear; and
a multiple of intermediate gears in meshing engagement with said sun gear and said ring gear, each of said multiple of intermediate gears including an inner portion of a rim, said inner portion of said rim being additive manufactured, and a multiple of gear teeth that extend from an outer portion of said rim of each of said multiple of intermediate gears about an axis; said inner portion of said rim additive manufactured to the outer portion at an interface, said gear teeth manufactured via subtractive manufacturing;
wherein said inner portion of said rim forms a matrix that defines a lattice structure.

8. The geared architecture as recited in claim 7 , wherein said inner portion of said rim forms an inner periphery.

9. The geared architecture as recited in claim 8 , wherein said interface is a mechanical interface.

10. The geared architecture as recited in claim 8 , wherein said interface is a bond layer.

11. The geared architecture as recited in claim 7 , wherein each of said multiple of intermediate gears is a double helical gear.

12. The geared architecture as recited in claim 11 , wherein said inner portion provides different characteristics along an axial length.

13. A method of manufacturing a gear, comprising:
subtractive manufacturing a multiple of gear teeth from an outer portion of a rim; and
additive manufacturing an inner portion of the rim as a matrix structure that defines a lattice structure.

14. The method as recited in claim 13 , further comprising additive manufacturing the inner portion of the rim to provide different characteristics along an axial length.

Assignees

• United Technologies Corp

Inventors

• Mccune Michael E

Classifications

• B22F5/085 Primary

  with helical contours · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• F16H55/17 Primary

  Toothed wheels (worm wheels F16H55/22; chain wheels F16H55/30) · CPC title

• F02C7/36

  Power transmission arrangements between the different shafts of the gas turbine plant, or between the gas-turbine plant and the power user ({F02C3/107 - F02C3/13 and} F02C7/32 take precedence; couplings for transmitting rotation F16D; gearing in general F16H) · CPC title