Adhesive Turbine Blade Workholding With UV-Cured Precision Positioning
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Solution Overview
Problem
Current workholding methods for turbine blades during manufacturing, such as low melt alloy encapsulation and hard point fixtures, face inefficiencies and health hazards due to thermal distortion, environmental concerns, and inconsistent product quality, as they rely on heavy metals, acids, and require multiple fixtures for machining, leading to part distortion and increased costs.
Innovation Solution
A workholding system utilizing a contoured surface shuttle with a transparent support body for adhesive attachment, featuring zero-point locating elements and UV-curable adhesives, allowing for precise positioning and machining of turbine blades with reduced load on the workpiece and enabling efficient debonding using hot water or thermal softening, thereby minimizing material waste and health risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If low melt alloy encapsulation is used to secure the workpiece, then the workpiece is firmly held during machining, but thermal stresses are introduced into the blade material causing distortion and the process becomes costly and environmentally harmful
Solution Approach 1:
The patent replaces the thermal-based low melt alloy encapsulation system with a mechanical adhesive bonding system. The adhesive composition cures to form a strong bond between the workpiece and fixture without requiring high temperatures, thereby eliminating thermal stress-induced distortion while maintaining firm holding strength during machining operations.
Solution Approach 2:
The patent changes the bonding mechanism from thermal (melted alloy) to chemical (adhesive curing). The adhesive composition undergoes a chemical transformation upon curing that provides strong bonding without the thermal effects that cause blade distortion, thus resolving the contradiction between holding strength and manufacturing precision.
2Strength
If hard point fixtures with clamping pressure are used to prevent part movement, then the workpiece is securely positioned, but the clamping pressure distorts the thin and compliant turbine blade
Solution Approach 1:
The patent replaces the mechanical clamping system with a chemical bonding system. The adhesive composition provides positioning stability through chemical adhesion rather than mechanical clamping pressure, eliminating the distortion caused by high localized forces on thin turbine blades while maintaining secure workpiece positioning.
Solution Approach 2:
The patent transitions from mechanical force-based positioning to chemical bond-based positioning. The adhesive composition provides sufficient bonding strength to prevent movement during machining without applying the high localized pressures that cause blade distortion, thus resolving the contradiction between positioning stability and shape accuracy.
3Adaptability or versatility
If multiple fixtures are used to machine different surfaces of the turbine blade, then all required surfaces can be accessed, but part distortion increases and product consistency decreases due to cumulative errors
Solution Approach 1:
The patent creates a universal fixture system where a single fixture design with contoured support bodies can accommodate multiple different turbine blade configurations and surfaces. The adhesive-based workholding allows the workpiece to be securely held in various orientations and positions, providing access to all required surfaces for machining while maintaining consistent accuracy through the reliable adhesive bond rather than cumulative fixture errors.
4Ease of operation
If heavy metals and acids are used in the workholding and removal process, then the workpiece can be securely held and released, but health hazards and environmental concerns increase
Solution Approach 1:
The patent replaces the hazardous chemical system (heavy metals and acids) with a safer adhesive bonding system. The adhesive composition can be removed using non-hazardous methods such as hot water or thermal softening, eliminating the need for acid baths and heavy metal handling while maintaining full workholding and release functionality.
Solution Approach 2:
The patent changes the chemical composition from hazardous materials (heavy metals, strong acids) to safer adhesive chemistry that can be cured and later removed using benign methods like hot water or controlled thermal softening. This resolves the contradiction between operational ease and harmful factors by providing effective workholding without the associated health and environmental risks.
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 system provides precise and efficient temporary holding of turbine blades during machining, reducing thermal distortion, environmental impact, and production costs by allowing for single-fixture machining with UV-curable adhesives and efficient debonding, ensuring consistent product quality and improved safety.
Implementation Method 1
curing the adhesive such that the workpiece is temporarily fixed in the predetermined position
Implementation Method 2
efficient debonding using hot water or thermal softening
Data Source
AI summary
A method and system temporarily holds a workpiece, most suitably an aero engine turbine blade element during manufacture. The workholding system includes a support body with a contoured body surface, complementary to a workpiece surface, formed of a transparent material to define a bonding zone. The support body is supported by a base to form a workpiece shuttle, and a bond station receives the workpiece shuttle. Complementary zero-point locating elements on the shuttle and station assure accurate positioning. The bond station further has workpiece locating elements configured to accurately position the workpiece on the shuttle in a predetermined position relative to the zero-point locating elements of the shuttle, thereby compensating for shuttle-to-shuttle variance. An adhesive, such as a UV curable adhesive, is applied to the bonding zone and cured by UV through the transparent material, thereby fixing the workpiece in the predetermined position.