Adaptive Airfoil Casting Machining for Dimensional Consistency
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Solution Overview
Problem
The manufacturing of gas turbine engine airfoils from castings faces challenges such as surface irregularities, increased cycle time, manual labor, environmental health and safety issues, and part-to-part dimensional inconsistencies due to the need to remove support, gating, and printout features, which conventional methods are ill-equipped to handle effectively.
Innovation Solution
An automated adaptive manufacturing system that uses 3D scanning, conformal mapping, and CNC tools to identify and correct dimensional abnormalities, classify features, and generate tool instructions for precise machining, thereby adjusting dimensions and removing features accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual methods (belt grinding, hand working) are used to remove support, gating, and printout features, then surface irregularities are removed, but part-to-part dimensional inconsistencies increase and cycle time increases
Solution Approach 1:
The patent replaces manual mechanical methods (belt grinding, hand working) with an automated CNC machining system. The system uses 3D scanning to capture the actual geometry of each casting, compares it to the nominal model, and automatically generates CNC toolpaths to remove support, gating, and printout features. This substitution of manual mechanical operations with automated computer-controlled machining eliminates the dimensional inconsistencies caused by manual variability while maintaining efficient cycle times through automation.
2Extent of automation
If traditional hard-coded robotic or CNC methods are used for feature removal, then automation is achieved, but the methods are unsuited to handle inherent part-to-part variance in rough castings
Solution Approach 1:
The patent implements a feedback-based adaptive machining system. Each casting is individually scanned using 3D scanning technology to capture its actual geometry, including variations from the nominal design. The scanned data is compared to the nominal model to identify deviations, and the system automatically adjusts the CNC toolpaths based on these measured variations. This closed-loop feedback mechanism enables the automated system to adapt to each part's unique characteristics, removing the rigidity of hard-coded programs while maintaining full automation.
Solution Approach 2:
The system transitions from static, pre-programmed CNC operations to dynamic, adaptive machining. The conformal-mapped nominal model is generated through conformal mapping techniques that proportionally adjust the dimensions of the ideal airfoil model based on the scanned part geometry. This dynamic model generation allows the system to automatically accommodate part-to-part variance, making the automation versatile and adaptable to each specific casting rather than requiring manual reprogramming for each variation.
3Ease of manufacture
If support, gating, and printout features are added during the investment casting process, then desirable design elements are achieved, but surface irregularities increase requiring removal operations
Solution Approach 1:
The system performs preliminary measurement and planning before the actual machining operation. The 3D scanning captures the as-cast geometry including all support, gating, and printout features. The conformal-mapped nominal model and difference map are generated in advance, identifying all areas requiring material removal. This preliminary characterization of each part's specific features allows the CNC system to automatically plan the optimal removal strategy, maintaining the manufacturing advantages of investment casting while preparing for precise subsequent machining.
Data Source
AI summary
A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.