Abrasive Flow Shields for Curved Passageway Smoothing

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Solution Overview

Problem

Additive manufacturing processes often result in internal passageway surfaces with roughness that can interfere with fluid flow, and existing abrasive machining techniques may cause non-uniform abrasion, especially in curved regions.

Innovation Solution

The use of shaped inserts within internal passageways to direct or divert abrasive media, including shields, augers, and restriction members, to tailor the abrasion process and ensure uniform smoothing of curved surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If abrasive media is forced through conduits to smooth inner surfaces, then surface roughness is reduced, but non-uniform abrasion occurs in curved regions

Engineering Contradiction:

Improvesurface uniformityVSAvoidabrasion uniformity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent applies local quality by using shaped inserts with varying cross-sectional areas positioned at specific locations within the passageway. These inserts create localized flow restrictions that redirect abrasive media to specific regions, ensuring uniform abrasion across the inner surface despite variations in passageway geometry. The inserts are tailored to match the specific curvature and geometry of the passageway sections they protect.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The shaped inserts serve as intermediary elements between the abrasive media and the passageway inner surface. These inserts modify the flow path and distribution of abrasive media, acting as mediators that ensure uniform contact and abrasion across curved surfaces. The inserts translate the bulk flow into controlled localized action.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If shaped inserts are used to direct abrasive media, then uniform smoothing is achieved, but device complexity increases

Engineering Contradiction:

Improvesurface uniformityVSAvoidinsert configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The solution segments the passageway into multiple sections, with shaped inserts positioned at strategic locations within each section. Each insert is a discrete component with a specific shape designed for its location, allowing the complex problem of uniform abrasion across the entire passageway to be divided into manageable local solutions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of trying to modify the abrasive media or the passageway itself, the invention inverts the approach by introducing removable inserts that temporarily alter the flow dynamics. These inserts can be easily inserted and removed, and their shapes are designed to compensate for the passageway geometry rather than requiring modification of the passageway.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If shields are positioned against curved inner surfaces, then protection from over-abrasion is achieved, but insertion difficulty increases

Engineering Contradiction:

Improvesurface protectionVSAvoidinsertion ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The shields are designed with flexible or movable characteristics that allow them to adapt to the curved inner surfaces during insertion and positioning. This dynamic design enables the rigid protection function while accommodating the geometric constraints of the passageway, making insertion feasible without requiring precise pre-alignment.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively protects curved surfaces from over-abrasion and ensures uniform smoothing of internal passageway surfaces, enhancing fluid flow by maintaining surface integrity and reducing surface roughness.

Implementation Method 1

Abrasive machining is a technique used to smooth surface roughness on the inner surfaces of conduits or passageways in additively manufactured components. The technique involves forcing an abrasive media through the conduits or passageways to abrade or wear away the surface roughness on the inner surfaces.

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

an auger positioned along a length of the shaft from the first end toward the second end, the auger comprising one or more vanes extending in helical fashion along the length of the shaft

Methodology Applied

Scientific EffectArchimedes Screw: Archimedes Screw

Implementation Method 3

a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS11364587B2Flow directors and shields for abrasive flow machining of internal passages

Publication Date: 2022.06.21 RTX CORP

AI summary

An insert apparatus for protecting a curved inner surface within a passageway from abrasion during an abrasive machining operation is disclosed. In various embodiments, the insert apparatus includes a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway and a shaft having a first end connected to the shell and a second end connected to a member configured to maintain the shaft within the passageway and the shell positioned against the curved inner surface during the abrasive machining operation.