Ceramic Drilling Layout for Back-Splash-Free Hole Machining

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Solution Overview

Problem

Efficient machining of deep, small-diameter holes in ceramic matrix composite (CMC) materials for gas turbine engines is challenging due to issues with surface integrity, tool wear, and productivity in existing methods like drilling, grinding, laser, and abrasive waterjet machining.

Innovation Solution

A drilling method using a liquid stream with abrasive particles or a laser beam, where the stream is impinged on the target region to remove material, with a drilling arrangement that allows gravitational draining of back-splash liquid to reduce interference, and a computerized 3D model is used to control the jet head for precise scanning in spiral patterns across 2D layers to form the hole.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional drilling, grinding, laser, or abrasive waterjet machining is used on CMCs, then holes can be formed, but surface integrity deteriorates, tool wear increases, and productivity decreases

Engineering Contradiction:

Improvesurface integrityVSAvoidmachining efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The machining process segments the liquid stream into discrete abrasive particles suspended in liquid, allowing controlled material removal through particle impact rather than continuous contact, which reduces tool wear and improves surface integrity while maintaining productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical drilling and grinding tools with a liquid stream-based system that uses fluid dynamics and particle erosion mechanisms, eliminating mechanical tool wear while achieving precise hole formation in CMCs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If a liquid stream is jetted at the target region to remove material, then productivity improves, but back-splash liquid interferes with the incoming stream reducing efficiency

Engineering Contradiction:

Improvematerial removal rateVSAvoidliquid stream interference

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The system extracts and removes the back-splash liquid from the target region using gravitational draining, preventing it from interfering with the incoming liquid stream and maintaining continuous high-speed material removal

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent positions the target region vertically above the jet head, utilizing the vertical dimension to enable gravitational draining of back-splash liquid away from the impingement zone, eliminating interference with the incoming stream

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If deep, small-diameter holes are drilled in CMCs, then cooling features are achieved, but existing methods produce poor surface integrity and high tool wear

Engineering Contradiction:

Improvecooling hole formationVSAvoidsurface integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a high-pressure liquid stream carrying abrasive particles to erode and remove material from CMCs, forming deep cooling holes without mechanical contact, thereby achieving the required geometry while maintaining excellent surface integrity and eliminating tool wear

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 enhances the efficiency of hole drilling in CMCs by minimizing interference from back-splash liquid, reducing tool wear, and improving productivity, resulting in better surface integrity and faster material removal.

Implementation Method 1

The liquid stream contains either abrasive particles or a laser beam. The liquid stream impinges the target region and the abrasive particles or the laser beam cause removal of material from the component at the target region

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

The liquid stream rebounds off of the component as back-splash liquid, and the drilling arrangement causes gravitational draining of the back-splash liquid from the target region to reduce interference between the back-splash liquid and the liquid stream

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS12103136B2Method and system for drilling ceramic

Publication Date: 2024.10.01 RTX CORP

AI summary

A method of machining includes mounting a component in a drilling machine. The component has a target region where the hole is to be drilled. The component and a jet head are situated relative to each other in a drilling arrangement in which the target region is at a first position that is vertically equal to or vertically above a second position at which the jet head is located. A liquid stream is jetted from the jet head and contains either abrasive particles or a laser beam. The stream impinges the target region, and the abrasive particles or the laser beam cause removal of material from the component to form the hole. The liquid stream rebounds off of the component as back-splash. The drilling arrangement causes gravitational draining of the back-splash from the target region to reduce interference between the back-splash and the liquid stream.