Abrasive Surface Force Control for Consistent Material Removal
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Solution Overview
Problem
The prolonged use of abrasive belts in surface processing for gas turbine engine components leads to inconsistent material removal due to wear, resulting in reduced effectiveness and increased processing costs, as areas processed early in the toolpath receive more material removal than those processed later.
Innovation Solution
Increasing the force between the abrasive surface and the component surface along the toolpath from a minimum to a maximum force compensates for wear, ensuring consistent material removal across the entire surface, achieved through a computer-generated toolpath and controlled force application using a pneumatic, hydraulic, or mechanical compliance system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the abrasive surface is used for prolonged processing, then the processing time is reduced, but the manufacturing precision deteriorates due to wear-induced inconsistent material removal
Solution Approach 1:
The patent applies dynamics by making the force parameter variable rather than constant. The force between the abrasive surface and component surface is dynamically adjusted along the toolpath, increasing from minimum to maximum force as processing progresses. This dynamic force adjustment compensates for abrasive wear and maintains consistent material removal rates throughout prolonged processing operations.
Solution Approach 2:
The patent changes the force parameter along the toolpath to compensate for abrasive wear. By increasing the force from minimum to maximum as processing progresses, the system maintains consistent material removal rates despite the deteriorating abrasive surface. This parameter change strategy allows prolonged use of the abrasive belt while preserving manufacturing precision.
2Manufacturing precision
If the abrasive surface force is increased to compensate for wear, then the material removal consistency is improved, but the device complexity increases due to force control systems
Solution Approach 1:
The patent applies preliminary action by pre-calculating and programming the force profile along the toolpath before processing begins. The computer-generated toolpath includes predetermined force variations that compensate for expected abrasive wear. This eliminates the need for complex real-time force adjustment systems, as the force control strategy is established in advance through software programming.
Solution Approach 2:
The patent employs feedback through computer-controlled systems that monitor and adjust the force applied by the abrasive surface. The force control system uses feedback from position sensors and processing parameters to maintain the predetermined force profile, ensuring consistent material removal while managing system complexity through automated control.
3Manufacturing precision
If the abrasive belt is replaced frequently to maintain effectiveness, then the manufacturing precision is improved, but the productivity decreases due to increased processing costs and downtime
Solution Approach 1:
The patent changes the force parameter along the toolpath to extend the usable life of the abrasive belt. By increasing force compensation for wear, the system maintains consistent material removal rates throughout the belt's service life, eliminating the need for frequent replacements and improving productivity while preserving surface finish quality.
Solution Approach 2:
The dynamic force adjustment allows the abrasive belt to maintain effectiveness throughout its entire service life. The system adapts to belt wear by varying force, enabling prolonged continuous operation without replacement and improving overall productivity while maintaining manufacturing precision.
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
This method allows for accurate control of material removal across the component surface, maintaining consistent results despite abrasive wear, reducing processing costs by optimizing material removal throughout the entire surface.
Implementation Method 1
The granular nature of the abrasive surface removes surface irregularities on the component surface as the abrasive surface moves over and against the component surface
Implementation Method 2
the force between the abrasive surface and the component surface is controlled by a pneumatic, hydraulic, mechanical or electrical compliance force system
Data Source
AI summary
The present invention provides an apparatus and method for processing a component surface by abrading the component surface using an abrasive surface. The apparatus comprises an abrasive surface which is rotatable about an axis extending parallel to said component surface. A support is provided for moving the abrasive surface or the component surface along a computer-generated toolpath and for applying a force between the abrasive surface and the component surface. The support increases the force between the abrasive surface and the component surface from a minimum force to a maximum force as the distance along the toolpath increases to maintain constant material removal from the component surface.