Compressor Blade Repair Fixture for Vibration-Stable Hybrid Manufacturing
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Solution Overview
Problem
Conventional methods struggle to precisely repair small or complex compressor blades due to vibration issues during subtractive manufacturing, leading to inefficiencies and often result in scrapping of damaged blades.
Innovation Solution
A mounting tool with support bases and a slot secures the compressor blade, allowing for simultaneous additive and subtractive manufacturing processes, using sacrificial supports to stabilize the blade and enable precise repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional subtractive manufacturing is used to repair compressor blades, then material can be removed to restore blade geometry, but vibration during the process leads to poor manufacturing precision
Solution Approach 1:
The mounting tool is prepared in advance with multiple support bases positioned to contact specific locations on the compressor blade. These support bases are configured before the repair process begins to provide stable support during both additive and subtractive manufacturing operations, preventing vibration and ensuring precision.
Solution Approach 2:
The mounting tool acts as an intermediary device between the compressor blade and the manufacturing equipment. It provides a stable interface with multiple support bases that distribute the blade's weight and prevent vibration during material removal, enabling precise subtractive manufacturing that would otherwise be impossible on small or complex blades.
2Productivity
If compressor blades are repaired using conventional methods, then some blades can be restored, but small or complex blades often must be scrapped due to vibration issues
Solution Approach 1:
The mounting tool is designed with multiple support bases that can be configured to accommodate different blade sizes, shapes, and geometries. This universal design allows the same tool to reliably support various types of compressor blades during repair, enabling both small and large blades to be repaired with consistent quality rather than scrapping small or complex ones.
3Duration of action of moving object
If additive manufacturing is used to add material to compressor blades, then blade life can be extended, but the process is time-consuming when combined with conventional repair methods
Solution Approach 1:
The mounting tool enables simultaneous additive and subtractive manufacturing processes to occur on the same compressor blade without repositioning. The blade remains secured to the tool throughout both material addition and removal operations, eliminating setup time and enabling hybrid manufacturing that extends blade life more efficiently than sequential conventional methods.
Data Source
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AI summary
Systems and methods for repairing compressor blades (50) using hybrid manufacturing techniques. A tool (100) for repairing a compressor blade has a plurality of support bases (116A, 116B), and a slot configured for securement of the compressor blade (50) to the mounting tool (100). The tool has a pair of support bases (116A, 116B), each of which is configured for the building of a sacrificial support (130, 140) thereon to stabilize the compressor blade (50) during repair. The tool is coupled to a hybrid manufacturing machinery and the sacrificial supports (130, 140) stabilize the compressor blade (50) during additive and subtractive manufacturing processes.