CMC Preform Machining During Partial Densification for Defect Removal
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Solution Overview
Problem
The formation process of ceramic matrix composite (CMC) components for gas turbine engines is challenging due to defects like broken fibers on the surface, which are typically addressed manually with messy and suboptimal results using machining tools.
Innovation Solution
A method involving preforming, partial densification, and machining or cutting of CMCs using autonomous adaptive machining with robotic tools to identify and remove defects, achieving an aerodynamically smooth finish, and dynamic force adjustment during the process, followed by full densification and potential re-machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual machining tools are used to remove broken fibers from CMC surfaces, then defects can be addressed, but the process becomes messy and requires significant cleanup with suboptimal results
Solution Approach 1:
The patent replaces manual mechanical machining tools with an automated robotic system that applies controlled mechanical action. The robotic arm with specialized end effector delivers precise, consistent cutting action without the mess and variability of manual operations, thereby improving both defect removal quality and process cleanliness.
Solution Approach 2:
The system incorporates real-time optical sensing that automatically detects broken fibers and guides the robotic cutting operation. The process self-regulates by sensing defect locations and autonomously navigating the cutting tool to remove only the necessary portions, eliminating the need for manual inspection and cleanup operations.
2Reliability
If manual machining operations are performed on CMCs, then broken fibers can be removed, but significant cleanup time and effort are required
Solution Approach 1:
Manual machining operations are replaced with an automated robotic system that performs both the cutting operation and the cleanup function. The robotic arm with controlled end effector precisely removes broken fibers and automatically clears the workspace, eliminating the separate manual cleanup step and reducing total processing time while maintaining defect removal effectiveness.
Solution Approach 2:
The robotic system performs defect removal and cleanup in a continuous automated sequence without interruption. The optical sensor continuously monitors the surface, identifies defects, guides the cutting tool, and the system automatically manages debris removal, creating an uninterrupted process flow that eliminates idle cleanup time.
3Reliability
If traditional machining methods are used on CMCs, then defects can be addressed, but the results are often less than optimal due to manual operation variability
Solution Approach 1:
Manual machining operations are replaced with an automated robotic system that eliminates human variability. The robotic arm with controlled end effector delivers consistent, repeatable cutting precision guided by optical sensing, ensuring uniform defect removal quality and precise cutting depth control that cannot be achieved through manual operations.
Solution Approach 2:
The system incorporates real-time optical sensing that provides continuous feedback on defect location, size, and orientation. This feedback loop allows the robotic control system to dynamically adjust cutting parameters and navigate the tool with high precision, ensuring optimal defect removal while maintaining consistent manufacturing precision across all operations.
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 reduces defect formation, improves yield, and minimizes waste by automating the removal of defects in CMCs, resulting in a more efficient and precise formation of gas turbine engine components.
Implementation Method 1
machining or cutting the CMCs during one or more of the preforming operations and the executing of the partial densification to remove defects from the CMCs
Implementation Method 2
The CMCs are then repeatedly compressed and heated until the desired blade or vane shape is achieved
Implementation Method 3
The CMCs are then repeatedly compressed and heated until the desired blade or vane shape is achieved
Data Source
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AI summary
A method of forming a component for a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes preforming the aerodynamic component into an initial desired shape using the CMCs, executing partial densification of the CMCs, repeating the preforming operations and the executing of the partial densification until a final desired shape of the aerodynamic component is achieved, machining or cutting the CMCs during one or more of the preforming operations and the executing of the partial densification to remove defects from the CMCs and executing a full densification of the CMCs.