Blade Retention Tooling for Precise Turbomachine Friction Welding
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Solution Overview
Problem
Existing gripping devices for friction welding blades to rotor elements in aircraft turbomachines lack robustness and precision, particularly in confined environments, leading to suboptimal weld quality and repeatability due to deformation and inadequate force transmission.
Innovation Solution
A tooling system comprising a fixed jaw with parallel arms and a movable jaw, integrated with pressure means and a control unit, providing enhanced rigidity and controlled motion to securely hold and align blades during friction welding, minimizing deformation and ensuring consistent positioning and force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gripping device is used to retain the blade during friction welding, then the blade can be held and positioned, but the device deforms under high axial and transverse forces leading to poor retaining accuracy
Solution Approach 1:
The gripping device is divided into a fixed jaw and a movable jaw that can independently position and clamp the blade. The fixed jaw provides stable positioning while the movable jaw applies clamping force, allowing each component to be optimized for its specific function and reducing overall deformation under load.
Solution Approach 2:
The gripping device incorporates a movable jaw that can dynamically adjust its position and apply force during the welding process. This dynamic capability allows the device to maintain optimal retaining accuracy throughout the welding cycle while distributing forces more effectively to minimize deformation.
2Volume of moving object
If the gripping device dimensions are reduced to fit confined spaces, then it can be used between blades, but it loses robustness and cannot withstand welding forces
Solution Approach 1:
By segmenting the gripping device into fixed and movable jaws with distinct functions, the design achieves high strength-to-volume ratio. The fixed jaw provides stable positioning with minimal volume, while the movable jaw delivers concentrated clamping force, allowing the overall device to fit in confined spaces without sacrificing force withstanding capacity.
Solution Approach 2:
The patent replaces a traditional single-piece mechanical gripper with a system that uses controlled motion and force application. The movable jaw mechanism substitutes brute-force structural strength with intelligent force distribution, enabling the device to withstand welding forces despite reduced dimensions suitable for confined spaces.
3Manufacturing precision
If the blade is retained firmly by the gripping device, then positioning accuracy is improved, but the device cannot accommodate blade variations
Solution Approach 1:
The movable jaw provides dynamic adjustment capability that allows the gripping device to adapt to blade variations while maintaining precise positioning. The fixed jaw ensures consistent reference positioning, while the movable jaw can be adjusted to accommodate different blade geometries, achieving both positioning accuracy and repeatability across multiple welding operations.
Solution Approach 2:
The gripping device design allows the blade itself to influence the positioning through the fixed jaw's reference surfaces, while the movable jaw automatically adjusts to apply optimal clamping force. This self-adjusting mechanism enables consistent positioning accuracy and repeatability without requiring manual reconfiguration for different blades.
4Productivity
If manual gripping operation is used, then device complexity is low, but welding cycle time is uncontrolled and productivity is reduced
Solution Approach 1:
The movable jaw mechanism provides controlled motion that can be automated through the friction welding machine's control system. This dynamic component enables programmable gripping and releasing cycles, allowing precise control of welding cycle time while the mechanical design remains relatively simple and integrated with the existing welding equipment.
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 tooling system improves weld quality and repeatability by minimizing deformation, enhancing force transmission, and allowing for automated control, thus reducing defects and increasing the efficiency of the welding process in confined spaces.
Implementation Method 1
The friction welding is a method for joining elements together, during which the heat is supplied by the friction between those elements.
Implementation Method 2
the elements are joined together under the action of a pressure (forging)
Data Source
AI summary
A tooling holds a blade during friction welding to a rotor element. The tooling includes a fixed jaw having a central part; two arms separated by a distance d for receiving at least one portion of the blade; and a fixed jaw body with bearing surfaces and a bore for receiving at least one portion of the blade. The bearing surfaces are configured to come into contact with the blade. A movable jaw includes a movable bearing surface that comes into contact with the blade, and pressure means that moves the movable jaw towards the fixed jaw body to press the blade.