CMC Cooling Hole Machining with Multi-Angle Laser Orientation
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Solution Overview
Problem
Conventional laser machining methods for forming cooling holes in ceramic matrix composite (CMC) components of gas turbine engines result in less than optimal geometries due to laser beam clipping, leading to tapered holes and reduced heat transfer effectiveness.
Innovation Solution
A laser machining system that orientates the CMC component in multiple positions to adjust the angle of attack of a conically-shaped laser beam, preventing unwanted clipping and allowing deeper penetration without tapering, thereby achieving precise and uniform cooling hole geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser machining methods are used to form cooling holes in CMC components, then the holes can be created, but the holes become tapered due to laser beam clipping on the sides and edges of the interior walls
Solution Approach 1:
The patent applies dynamics by making the component movable during the laser machining process. The component is oriented in multiple different positions (orientations) while being lasered, allowing the laser beam to machine different sections at varying angles. This dynamic repositioning prevents the laser beam from clipping the sides and edges of the interior walls, thereby eliminating the taper effect and achieving uniform cylindrical hole geometry throughout the depth of the component.
2Length of moving object
If conventional laser machining methods are used, then cooling holes can be formed, but penetration depth is limited as beam clipping and taper angle increase with depth
Solution Approach 1:
The patent overcomes the depth limitation by dynamically repositioning the component during machining. As the laser beam penetrates deeper into the component, the component is reoriented to different positions, which changes the angle at which the laser beam intersects the interior walls. This prevents beam clipping at greater depths and maintains consistent hole geometry, enabling penetration much deeper than conventional methods while preserving geometric precision throughout the entire depth.
Solution Approach 2:
The patent introduces an additional dimension of control by varying the angular orientation of the component relative to the laser beam. Instead of maintaining a fixed orientation, the component is rotated or tilted to different angles during the machining process. This angular dimension allows the laser beam to access and machine interior walls at depths that would otherwise be blocked by clipping, thereby extending penetration depth while maintaining geometric consistency.
3Length of moving object
If the laser beam penetrates deeper into the component, then deeper holes can be formed, but the angle of inclination of the taper increases with depth
Solution Approach 1:
The patent dynamically adjusts the component's orientation as a function of depth. At shallower depths, one orientation may be used, but as the laser beam penetrates deeper, the component is reoriented to different positions. This dynamic adjustment compensates for the increasing taper angle that would naturally occur at greater depths, maintaining a consistent cylindrical geometry throughout the entire depth of the hole by preventing beam clipping at each depth level.
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 system ensures optimal film effectiveness and deeper penetration of the laser beam, improving the operational service life of CMC components by preventing unwanted clipping and maintaining uniform geometry throughout the cooling holes.
Implementation Method 1
a laser source configured to machine the opening with a conically-shaped laser beam
Data Source
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AI summary
A system (100) and a method for machining openings (210) in a component (200) are provided. The laser system (100) includes features for machining an opening (210) into a component (200), such as a cooling hole for a CMC component (200) of a gas turbine engine . The component (200) is oriented in a first position (P1) and lasered while oriented in the first position (P1) to form a portion of the opening (210). The component (200) is then oriented to a second position (P2) and lasered while oriented in the second position (P2) to form another portion of the opening (210). The component (200) is alternated between the first and second positions (PI, P2) until the predetermined geometry of the opening (210) is formed. The component (200) is oriented in the first and second positions (PI, P2) such that the laser beam can machine the component (200) without clipping areas that are not desired to be machined.