Turbomachine Blade Edge Reinforcement Forging Process
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Solution Overview
Problem
The production of metallic reinforcements for turbomachine blades, particularly for the leading or trailing edges, is complex and costly due to the need for numerous rework operations and sophisticated tooling, especially when using composite materials.
Innovation Solution
A method involving forging deformation of a metal bar to create a complex shape reinforcement, using a series of steps including bending, stuffing, and spinning to form the reinforcement, significantly reducing production costs and simplifying the process by utilizing simple tools and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional milling from a block of material is used to produce metal reinforcement, then manufacturing precision can be achieved, but production costs increase and device complexity increases
Solution Approach 1:
The patent changes the manufacturing parameters by switching from subtractive milling to additive forging processes. The metal bar is heated to austenitic temperature and then forged through dies to create the complex reinforcement geometry, fundamentally changing the manufacturing approach to reduce costs while maintaining precision
Solution Approach 2:
The manufacturing process is segmented into distinct stages: heating the metal bar to austenitic temperature, forging through first and second dies to create intermediate shapes with fins, and final deformation to achieve the target geometry. This segmentation allows each stage to be optimized independently
2Manufacturing precision
If complex tooling is used for producing metal reinforcement, then manufacturing precision can be maintained, but device complexity increases
Solution Approach 1:
The tooling is segmented into separate heating means and forging dies. The heating means prepares the metal bar by bringing it to austenitic temperature, while the first and second dies perform sequential forging operations. This segmentation simplifies each individual tooling component while maintaining overall manufacturing precision
Solution Approach 2:
The metal bar is pre-heated to austenitic temperature before forging operations begin. This preliminary heating action prepares the material to be more formable and reduces resistance during the subsequent forging steps, allowing simpler tooling to achieve complex geometries
3Manufacturing precision
If numerous rework operations are performed on metal reinforcement, then manufacturing precision can be achieved, but productivity decreases
Solution Approach 1:
The forging process continues uninterrupted through multiple deformation stages. The metal bar is heated once and then subjected to sequential forging operations through the first die, second die, and final deformation without cooling or re-heating interruptions, maintaining continuous useful action and high productivity
Solution Approach 2:
The metal bar is pre-heated to austenitic temperature before the forging sequence begins, and this heated state is maintained throughout all deformation operations. This preliminary preparation eliminates the need for repeated heating and cooling cycles, significantly improving productivity
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 enables the efficient and cost-effective production of complex-shaped metallic reinforcements for turbomachine blades, reducing manufacturing costs and time while maintaining the structural integrity required for high-stress applications.
Implementation Method 1
a step of deformation by forging of a metal bar, the metal being pushed in a direction essentially perpendicular to the longitudinal axis of the bar through two dies so as to obtain an intermediate piece
Implementation Method 2
By forging deformation step is meant here an operation for shaping metals by forging consisting in pushing a ductile material (made ductile by heating) through a hole or a die. Thus, during the first step of deformation by forging of the metal bar, the heated solid metal is placed in a tool so as to force the material out through an orifice or a die arranged in the tool by plastic flow.
Data Source
Figure 1~2
Figure 3~4E
Figure 5A~5B
AI summary
The present invention relates to a method for producing a solid component which in succession involves a step (240) of deforming a metal bar (40) by forging using two dies in order to obtain an intermediate component (50) comprising two fins (51) one on each side of a solid part (53) capable of forming the base (39) of said metal reinforcement (30), said two fins (51) being at a divergent angle a; a step (250) of deforming said fins (51) of said intermediate component (50), altering said divergent angle a, so as to obtain the final shape of the turbomachine blade leading edge or trailing edge metal reinforcement (30).