Compressor Blade Compaction Alignment Using Polygon Pin References
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Solution Overview
Problem
The existing manufacturing process for turbomachine compressor blades, specifically the 'core-shaped leading edge' method, faces challenges in precisely and robustly aligning the stack for machining, leading to tedious installations and risks of impacting the core during pin removal, which complicates the depinning operation and may result in core damage.
Innovation Solution
Defining a polygon by primary bores provides a more precise and stable frame of reference for fixing the stack, allowing a single installation operation and enabling the removal of titanium pins without compromising the core's integrity, using shouldered pins to create a circular surface for precise alignment and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If four pins are aligned parallel to a longitudinal edge of the stack, then they can block bores in the core for clamping during machining, but they do not allow robust and precise alignment of the stack in relation to the main face of the core
Solution Approach 1:
The patent introduces a fifth pin positioned asymmetrically with respect to the four aligned pins, creating an asymmetric distribution pattern. This asymmetric arrangement provides both clamping capability and robust alignment references, as the offset position of the fifth pin creates a stable triangular or polygonal reference pattern that enables precise positioning relative to the main face of the core.
Solution Approach 2:
The patent combines multiple functions into the pin arrangement: the five pins simultaneously serve as clamping references (blocking bores for clamping devices) and alignment references (providing stable geometric patterns for positioning). This merging of clamping and alignment functions into a single integrated pin configuration eliminates the need for separate alignment features.
2Manufacturing precision
If a second installation operation is carried out to precisely locate the titanium pin, then machining perpendicularity can be achieved, but the process becomes tedious and time-consuming
Solution Approach 1:
The patent performs preliminary alignment by positioning all five pins (including the offset fifth pin) before compaction, creating a pre-established reference framework. The titanium pin's position is predetermined by the geometric relationship with the other pins, so no subsequent alignment operations are needed - the perpendicularity is built into the initial configuration.
Solution Approach 2:
The pin arrangement serves itself for alignment purposes. The geometric configuration of the five pins automatically provides the reference framework needed for machining, without requiring external alignment operations or additional positioning steps. The system is self-aligning through its inherent geometric relationships.
3Measurement precision
If pins are positioned far from the center of gravity of the core, then they can define reference frames, but it becomes difficult to fix the stack precisely and robustly on its support
Solution Approach 1:
The asymmetric positioning of the fifth pin relative to the four aligned pins creates a balanced reference pattern that improves fixing stability. The offset position distributes the reference points more favorably across the core surface, creating a more stable geometric configuration for mounting while maintaining precise reference definition.
Solution Approach 2:
The patent transitions from a one-dimensional linear arrangement of pins to a two-dimensional distributed pattern. The fifth pin adds a new spatial dimension to the reference frame, creating a polygonal or triangular pattern that provides superior stability and rigidity compared to a simple linear or clustered arrangement.
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 approach reduces cycle times, enhances dimensional robustness, and ensures precise alignment, minimizing the risk of core damage during pin removal, while maintaining the integrity of the core and existing process elements.
Implementation Method 1
It is welded to the intrados and extrados sheets using diffusion welding
Implementation Method 2
The stack is then hot isostatic compacting (HIC). During this operation, the two sheets closely match the shape of the core
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a method for producing a turbomachine compressor blade, comprising the following steps: - installing primary pins (26) comprising a material other than a titanium-based alloy in primary bores (20) of a core, the primary bores forming at least one polygon, and installing a secondary pin made of titanium-based alloy in a secondary bore of the core; - producing a stack (2) of a suction-face sheet (4), a core (14) and a pressure-face sheet (6); - compacting the stack; - removing the primary pins (26) from the primary bores (20); - removing the secondary pin from the secondary bore; and - taking the core (14) away from the stack.