Bladed Disc Manufacturing with Temporary Bridging Ring
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Solution Overview
Problem
The manufacturing of one-piece blisks for aircraft turbine engines using abrasive water jet cutting followed by milling faces issues with blade deformations and vibrations, leading to reduced feed rates and increased production times and costs due to tool wear.
Innovation Solution
The method involves cutting a block of material to reveal blade preforms with a retaining ring that connects them radially, allowing high feed rates and reducing vibrations, followed by removing the connecting means to prevent deformations and vibrations during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting by abrasive water jet is used to remove material before milling, then manufacturing time and cost are reduced, but blade deformations and vibrations increase
Solution Approach 1:
The invention segments the manufacturing process into distinct phases: first cutting all blades simultaneously from the block using abrasive water jet to remove bulk material, then separately supporting each blade during individual milling operations. This segmentation allows high-speed bulk removal while enabling precise control during finishing operations.
Solution Approach 2:
The invention performs preliminary cutting of all blade preforms from the block before any milling operations. By pre-shaping the blades with abrasive water jet cutting while they are still supported by the block, the invention enables subsequent precise milling with reduced vibrations, as the blades are already接近 their final shape and properly supported.
2Productivity
If high feed rates are applied to tools during manufacturing, then production time is reduced, but blade vibrations increase and quality deteriorates
Solution Approach 1:
The invention performs preliminary cutting of all blade preforms from the block before any milling operations. By pre-shaping the blades with abrasive water jet cutting while they are still supported by the block, the invention enables subsequent precise milling with reduced vibrations, as the blades are already接近 their final shape and properly supported.
Solution Approach 2:
The invention uses the block itself as an intermediary supporting structure during the cutting phase. The block provides natural support to all blade preforms simultaneously, allowing high-speed cutting without vibrations. This eliminates the need for external support structures that would limit feed rates.
3Ease of manufacture
If blades are left unsupported during cutting, then tool wear is reduced, but blade deformations increase and production time increases
Solution Approach 1:
The invention performs preliminary cutting of all blade preforms from the block before any milling operations. By pre-shaping the blades with abrasive water jet cutting while they are still supported by the block, the invention enables subsequent precise milling with reduced vibrations, as the blades are already接近 their final shape and properly supported.
Solution Approach 2:
The invention uses the block itself as an intermediary supporting structure during the cutting phase. The block provides natural support to all blade preforms simultaneously, allowing high-speed cutting without vibrations. This eliminates the need for external support structures that would limit feed rates.
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 significantly reduces blade deformations and vibrations, enabling higher feed rates, shorter production times, and lower tool wear, thus reducing production costs while maintaining the quality of the blisk.
Implementation Method 1
a step of cutting a block of material by abrasive water jet
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The present invention relates to a method for producing a one-piece bladed disc, comprising: a step in which an abrasive water jet is used to cut a block of material (100), in such a way as to leave behind blade preforms (102) extending radially from a disc (4), while keeping material forming bridging means (112) between directly consecutive blade preforms, the cutting step being performed in such a way that said bridging means form basically a ring radially remote from the disc and interconnecting the blade preforms at a distance radially inward from their tips; and then a step of removing the bridging means (112).