GAS TURBINE ENGINE SLOTTING TOOLS

Description

BACKGROUND

[0001] This disclosure relates to a gas turbine engine, and more particularly to a tool for a slot in a gas turbine engine.

[0002] Gas turbine engines typically include a compressor section, a combustor section and a turbine section. In general, during operation, air is pressurized in the compressor section and is mixed with fuel and burned in the combustor section to generate hot combustion gases. The hot combustion gases flow through the turbine section, which extracts energy from the hot combustion gases to power the compressor section and other gas turbine engine loads.

[0003] Various areas of a gas turbine engine including slots within engine hubs may accumulate grease and debris during operation. As an example, fan blades are received in slots in a rotor.

[0004] In FR 2 886 179 A1, there is provided a method of machining a groove in the periphery of a component, such as a disc (12) of a turbine, consists of forming the groove by stitching. It then consists of subj ecting the walls of the groove to an abrasive polishing, by the translation of a polishing tool (24) mounted on the stitching machine. An independent claim is also included for the machining device applying this method for forming a groove in the periphery of a component.

[0005] In US 2012 / 005850 A1, there is provided a cleaning implement for cleaning a surface, in particular for cleaning grout or the like textured surfaces. In particular, the invention allows for a complete cleaning of a surface with a multi-component cleaning implement having a replaceable melamine member that is held by a supporting member. To allow ease of cleaning, the supporting member further includes an abrasive film and an absorbent sponge allowing the consumer to thoroughly clean with a melamine member yet allow removal of all residual melamine and dirty water by the use of a single all inclusive cleaning implement.SUMMARY

[0006] From one aspect, there is provided a tool for a slot in a gas turbine engine that includes a head configured to be received in the slot and including a first rounded groove and a second rounded groove, a first cylindrical pad received in the first rounded groove, and providing a first curved outward facing surface, wherein the first cylindrical pad is removably bonded to the head with an adhesive or attached to the head, and a second cylindrical pad received in the second groove, and providing a second curved outward facing surface and disposed opposite from the first pad, wherein the second cylindrical pad is removably bonded to the head with adhesive or attached to the head, wherein the head includes extension portions that provide side surfaces and the extension portions are above the pads when in use to allow a downward force to compress the pads.

[0007] In a further embodiment according to any of the above, a handle extends from the head.

[0008] In a further embodiment according to any of the above, the handle and the head is comprised of plastic, and the first pad is comprised of a second material different from plastic.

[0009] In a further embodiment according to any of the above, the first pad and the second pad are elongated in a first direction and are disposed opposite the head from one another in a second direction substantially perpendicular to the first direction.

[0010] In a further embodiment according to any of the above, the first pad and the second pad are formed of one of an abrasive, a rubber, and / or a sponge material, and the adhesive is comprised of one or more of acrylics, silicones, epoxies, urethanes, and imides.

[0011] In a further embodiment according to any of the above, the adhesive is comprised of one or more of acrylics, silicones, epoxies, urethanes, and imides.

[0012] A method of finishing a slot in a gas turbine engine using a tool of the present disclosure includes inserting the tool into the slot. The first pad is moved along a channel at a first circumferential edge of the slot and the second pad is moved along a second channel at a second circumferential edge of the slot circumferentially opposite the first edge.

[0013] In a further embodiment according to any of the above, the tool is contoured to match the slot.

[0014] In a further embodiment of the above method, a blade is removed from the slot before inserting a tool into the slot.

[0015] In a further embodiment of the above method, debris and / or grease is removed from the first and second channels with the first and second cylindrical pads.

[0016] In a further embodiment of the above method, the first and second channels are polished with the first and second cylindrical pads.

[0017] In a further embodiment according to any of the above, the tool is so configured that one of the first and second cylindrical pads may be removed from a location on the head, the removed pad is replaced with a third pad at the location, and the third pad may be removably bonded to the head with an adhesive.

[0018] In a further embodiment of the above method, the slot is eddy-current tested at an area where the pads had contacted the slot.

[0019] In a further embodiment of the above method, the tool is moved along the slot in an axial direction relative to an engine central longitudinal axis.

[0020] In a further embodiment according to any of the above, the head provides a third curved outward facing surface that receives the first pad, and the head provides a fourth curved outward facing surface that receives the second pad.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 schematically illustrates an example gas turbine engine. Figure 2 illustrates a cross sectional view of a portion of a fan section of a gas turbine engine. Figure 3 illustrates an example tool for a slot in a gas turbine engine removing grease and / or debris from a slot. Figure 4 illustrates the example tool of Figure 3. Figure 5 schematically illustrates replacement of a pad in the example tool of Figures 3 and 4. Figure 6 illustrates a side view of the example tool of Figure 3. Figure 7A illustrates the example tool of Figures 3-6 in a slot of a fan hub of a gas turbine engine. Figure 7B illustrates a cross sectional view of the example tool of Figures 3-7A in a slot of a fan hub of a gas turbine engine. Figure 8 schematically illustrates non-destructive testing performed on a slot in a gas turbine engine. Figure 9 illustrates a portion of another example tool. Figure 10 illustrates a flow chart of a method of inspection of a gas turbine engine component. Figure 11 illustrates a flow chart of a method of finishing a slot in a gas turbine engine. Figure 12 illustrates a flow chart of a method of manufacturing a tool for finishing a slot in a gas turbine engine. DETAILED DESCRIPTION

[0022] An example gas turbine engine 10 is schematically illustrated in Figure 1. The gas turbine engine 10 includes a compressor section 12, a combustor section 14 and a turbine section 16, which are arranged within a housing 24. In the example illustrated, high pressure stages of the compressor section 12 and the turbine section 16 are mounted on a first shaft 20, which is rotatable about an engine central longitudinal axis A. Low pressure stages of the compressor section 12 and turbine section 16 are mounted on a second shaft 22 which is coaxial with the first shaft 20 and rotatable about the axis A. In the example illustrated, the first shaft 20 rotationally drives a fan 42 that provides flow through a bypass flow path 19. Although depicted as a two-spool turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with two-spool turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures.

[0023] Figure 2 illustrates a cross sectional view of a portion of the fan 42. Although one slot 59 and one blade 61 is shown in Figure 2 for illustrative purposes, the fan 42 includes a number of slots 59 in a fan hub 60 receiving fan blades 61. As shown, the slot 59 may accumulate debris and / or grease G. Although a slot in a fan hub is disclosed in this example, other slots in gas turbine engines may benefit from this disclosure.

[0024] Figure 3 illustrates an example tool 62 received in the slot 59 for removal of grease and / or debris. In addition to or as an alternative to grease and / or debris removal, in some examples, the tool 62 may be used in other finishing operations, such as polishing (smoothing the surface of) the slot 59. That is, "finishing," as used in this disclosure, may include removal of grease and / or debris and polishing. In the illustrated example, the fan blade 61 is removed from the slot 59 before the tool 62 is received in the slot 59. Although one slot 59 is shown for illustrative purposes, the tool 62 may be used to finish multiple slots.

[0025] Figure 4 illustrates an example tool 62 that may be used for finishing operations in the slot 59. The example tool 62 includes a head 65 and one or more pads 63A, 63B removably bonded to the head 65 with an adhesive 64. Example adhesives 64 may include acrylics, silicones, epoxies, urethanes, and / or imides. A handle 67 may extend from the head 65 for a user to engage to maneuver the tool 62 within a slot 59.

[0026] The head 65 includes a groove 66A to receive the pad 63A, which is in the shape of an elongated cylindrical rod and removably bonded to the groove 66A by an adhesive. As will be explained below, other shapes are contemplated within the scope of this disclosure. The groove 66A is rounded to accommodate the cylindrical shape of the pad 63A. The second pad 63B is substantially similar to the first pad 63A and removably bonded to a groove 66B by an adhesive opposite the head 65 from the pad 63A and groove 66A. The example pads 63A, 63B and their respective grooves 66A, 66B are each elongated in a first direction 70 and are opposite the head 65 from one another in a second direction 72 substantially perpendicular to the first direction 70. In the example, the grooves 66A, 66B are convex, and the pads 63A, 63B provide concave curved outward facing surfaces 69A, 69B. In some examples, the pads 63A, 63B may be made of abrasives, rubbers, or sponges. In some examples, the pads 63A, 63B are made of a silicone carbide filled rubber.

[0027] The handle 67 extends from an upper surface 74 of the head 65. In the example, the handle 67 and the head 65 are monolithic. In some examples, the handle 67 and the head 65 are formed by a 3D printing process, but other manufacturing processes are also contemplated. In some examples, the handle 67 and head 65 are formed of plastic material, which may include acrylics, epoxies, nylons, imides, polyethylenes, polypropylenes, styrenes, carbonates and / or polyesters. In some examples, the handle 67 and head 65 may be formed by filled plastics. Filler examples may include carbon, nanotubes, glass, and / or ceramic.

[0028] By removably bonding the pads 63A, 63B to the head 65 with an adhesive, the pads 63A, 63B are fixed to the head 65 strongly enough to perform finishing operations, while still being easily removed from the head 65 when replacement of the pads 63A, 63B is desired. That is, the adhesive provides a high enough shear strength for finishing operations to be performed and a low enough peel strength for removal of the pads 63A, 63B when replacement is desired.

[0029] As shown schematically in Figure 5, any one or both of the pads 63A, 63B may be replaced one or multiple times, with the head 65 and handle 67 being reused after pad replacement. As shown, a used pad 63U has been removed and replaced. Efficiency and cost savings is achieved by reuse of the head 65 and handle 67, which may be relatively expensive to manufacture. Moreover, by adhering the pads 63A, 63B to the head 65, the tool 62 may be assembled free of any fasteners, including metal fasteners, avoiding metal on metal contact with the slots 59.

[0030] Figure 6 illustrates a side view of the tool 62. The handle 67 extends from the upper surface 74 of the head 65 along a central axis 76 of the handle, which forms an angle 78 with the upper surface 74. In some examples, the angle 78 is less than 90 degrees. In other examples, the angle 78 is 90 degrees.

[0031] Figures 7A and 7B illustrate the example tool 62 applied to a slot 59 in a fan hub 60 for finishing. As shown in Figure 7A, the slot 59 extends axially from a first axial end 80 of the hub 60 to a second axial end 82 opposite the first axial end 80. The tool 62 may be inserted into the slot 59 at one of the axial ends 80, 82, and moved along the slot 59 in the direction 84 for finishing the slot 59. In the example, the direction 84 is substantially parallel to the engine central longitudinal axis (see Figure 1). That is, the direction 84 may be in the forward and / or aft directions. The direction 84 is also substantially parallel to the direction 70 of elongation of the pads 63A, 63B (see Figure 3). The tool 62 is configured to finish channels 86A, 86B at opposed circumferential edges of the slot 59 and extending axially along the length of the slot 59.

[0032] Figure 7B shows a cross section of the head 65 and pads 63A, 63B within the slot 59. The pads 63A, 63B are received against the rounded channels 86A, 86B circumferentially opposite one another at the radially inner end 88 of the slot 59. The pads 63A, 63B are positioned to finish the respective channels 86A, 86B as the tool 62 moves along the slot 59. The friction of the pads 63A, 63B against the surface of the slot 59 at the channels 86A, 86B can polish and remove grease and / or debris. In some examples, other tools may be used to finish other areas of the slot 59.

[0033] The example head 65 includes the upper surface 74, the grooves 66A, 66B, a lower surface 90 opposite the head 65 from the upper surface 74, and side surfaces 92 and 94. The lower surface 90 extends from the groove 66A to the groove 66B. The side surface 92 extends from the groove 66A to the upper surface 74. The side surface 94 opposite the head 65 from the side surface 92 extends from the groove 66B to the upper surface 74. In the example, the upper surface 74 and the lower surface 90 are substantially parallel.

[0034] A surface 96 of the slot 59 extends circumferentially from the channel 86A to the channel 86B and is elevated radially outward relative to the channels 86A, 86B. The lower surface 90 of the tool 62 is raised relative to the lowermost points of the pads 63A, 63B to provide a contour to match the slot 59. The portions of the head 65 that provide surfaces 92 and 94 are above the pads 63A, 63B when in use to allow a downward force to compress the pads 63A, 63B for finishing. In some examples, the tool 62 may be configured to finish the surface 96, such as by providing a pad at the surface 90 of the tool 62.

[0035] As shown schematically in Figure 8, after the slot 59 is cleaned and / or polished, non-destructive inspection may be performed on the slot 59. As shown in the example, one example of non-destructive inspection is eddy current testing, a known method for testing for fatigue or cracks in metal in gas turbine engine components in which a probe 97 uses electromagnetic induction to detect flaws. The tool 62 (not shown) provides a smooth surface in and removes debris and / or grease from the slot 59 prior to eddy current testing. The smooth surface and lack of debris and / or grease provides for improved accuracy in the eddy current measurements. In some examples, the eddy current testing is performed on an area that was finished by the pads 63A, 63B, such as the channels 86A, 86B (Figures 7A & 7B).

[0036] Figure 9 schematically illustrates a portion of another example tool 162. It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. A substantially flat pad 163 may be removably bonded via an adhesive 164 to a convex curved surface 166 of the tool 162, such that the pad 163 provides a convex curved outward facing surface 169. One of ordinary skill in the art having the benefit of this disclosure would recognize that other geometries could be used to provide curved outward facing surfaces.

[0037] Figure 10 illustrates a flowchart of a method 200 of inspection of a gas turbine engine component. At 202, a tool 62 / 162 is applied to a slot 59. At 204, non-destructive inspection is performed on the slot 59.

[0038] Figure 11 illustrates a flowchart of an example method 300 of finishing a slot 59 in a gas turbine engine. One or more of the steps may be performed, and the steps are not limited to the order shown. At 302, a blade may be removed from the slot 59. At 304, the tool 62 / 162 is inserted into to the slot 59. At 306, the method may include removing debris and / or grease from the slot 59 with the tool 62 / 162. At 308, the method may include polishing the slot 59 with the tool 62 / 162. At 310, the method may include removing a previous pad 63A, 63B from the head 65 and replacing the previous pad 63A, 63B with a new pad. Pads 63A, 63B may be replaced before or after the tool 62 / 162 is applied to a slot 59.

[0039] Figure 12 illustrates a flowchart of a method 400 of manufacturing a tool for finishing a slot in a gas turbine engine. At 402, a head 65 and a handle 67 extending from the head 65 are provided. This step may include 3D printing the handle 67 and the head 65 in some examples. At 404, an adhesive is applied to the head 65. At 406, a pad 63A, 63B is bonded to the head 65 with the adhesive. In some examples, the method includes applying the adhesive to a groove in the head 65 and bonding the pad 63A, 63B to the groove. In some examples, the method includes mechanically affixing the pad to the head 65 while the adhesive cures and removing mechanical means after cure is complete.

[0040] Although the disclosed examples are directed to slots in fan hubs, other slots in gas turbine engines may benefit from this disclosure. Moreover, although specific geometries are disclosed in some examples, other geometries may be utilized to accommodate the slot to be finished.

[0041] Although embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the scope and content of this disclosure.

Claims

1. A tool (62) for a slot (59) in a gas turbine engine (10), the tool (62) comprising: a head (65) configured to be received in the slot (59) and including a first rounded groove (66A) and a second rounded groove (66B); a first cylindrical pad (63A) received in the first rounded groove (66A), and providing a first curved outward facing surface (69A); wherein the first cylindrical pad is removably bonded to the head (65) with adhesive (64), or attached to the head (65); and a second cylindrical pad (63B) received in the second rounded groove (66B), and providing a second curved outward facing surface (69B) and disposed opposite from the first pad (63A); wherein the second cylindrical pad is removably bonded to the head (65) with adhesive (64), or attached to the head (65), wherein the head includes extension portions that provide side surfaces (92, 94) and the extension portions are above the pads (63A, 63B) when in use to allow a downward force to compress the pads (63A, 63B).

2. The tool (62) as recited in any preceding claim, comprising a handle (67) extending from the head (65).

3. The tool (62) as recited in any preceding claim, wherein the handle (67) and the head (65) comprise plastic, and the first pad (63A) comprises a second material different from plastic.

4. The tool (62) as recited in any preceding claim, wherein the first pad (63A) and the second pad (63B) are elongated in a first direction (70) and are disposed opposite the head (65) from one another in a second direction (72) substantially perpendicular to the first direction (70).

5. The tool (62) as recited in any preceding claim, wherein the first pad (63A) and the second pad (63B) are formed of an abrasive, a rubber, and / or a sponge material.

6. The tool (62) as recited in any preceding claim, wherein the adhesive (64) comprises one or more of acrylics, silicones, epoxies, urethanes, and / or imides.

7. The tool (62) as recited in any preceding claim wherein the tool is contoured to match the slot.

8. The tool (62) as recited in any preceding claim, wherein the tool is so configured that one of the first and second cylindrical pads may be removed from a location on the head, the removed pad is replaced with a third pad at the location, and the third pad may be removably bonded to the head with an adhesive.

9. A tool (62) as recited in claim 1, wherein the head (65) provides a third curved outward facing surface that receives the first pad (63A), and the head (65) provides a fourth curved outward facing surface that receives the second pad (63B)