Compressor Blade Repair Fixturing for Vibration-Stable Hybrid Manufacturing
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Solution Overview
Problem
Conventional methods struggle to effectively repair compressor blades with complex geometries, particularly small and thin blades, due to vibration issues during hybrid manufacturing processes, leading to inefficiencies and often requiring scrapping.
Innovation Solution
A mounting tool with adjustable fasteners and support bases that stabilize the blade during hybrid manufacturing, allowing simultaneous additive and subtractive processes by securing the blade within a slot and using sacrificial supports to maintain stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional repair methods are used on small and thin compressor blades, then the blades can be repaired, but vibrations occur during hybrid manufacturing processes leading to repair failure
Solution Approach 1:
The mounting tool is divided into multiple functional components including a body, slot, support bases, and fasteners. Each component serves a specific function in stabilizing the blade during repair, with the slot providing positioning and the support bases providing additional stability points.
Solution Approach 2:
The mounting tool acts as an intermediary device between the hybrid manufacturing machine and the compressor blade. It provides a stable interface that allows the blade to be securely held while accommodating the manufacturing processes, transferring stability from the tool to the blade.
2Reliability
If compressor blades are secured during hybrid manufacturing, then vibration is reduced, but the complexity of the mounting tool increases
Solution Approach 1:
The mounting tool is designed to perform multiple functions: securing the blade in position, providing support during additive manufacturing, accommodating subtractive manufacturing operations, and enabling vibration reduction. This multi-functionality reduces the need for multiple separate devices.
Solution Approach 2:
The fasteners are designed with adjustable parameters, allowing them to be tightened or loosened as needed. This adjustability provides flexibility in securing different blade sizes and geometries without requiring completely different mounting tools.
3Productivity
If hybrid manufacturing processes are used for compressor blade repair, then repair efficiency is improved, but vibration issues arise during the process
Solution Approach 1:
The support bases are strategically positioned to counterbalance the blade during manufacturing operations. They provide opposing support forces that counteract the vibrations generated during additive and subtractive manufacturing processes.
Solution Approach 2:
The mounting tool is designed with vibration-reducing features built in before the manufacturing process begins. The slot and support bases are configured to minimize vibration generation and transmission during the repair operations.
Data Source
AI summary
Systems and methods are provided for repairing compressor blades using hybrid manufacturing. A mounting tool for use in repairing a turbine component includes a slot formed in the mounting tool. The slot is configured to receive the turbine component for securing the turbine component to the mounting tool. The mounting tool includes at least one fastener engageable with the turbine component and capable of retaining the turbine component within the slot; and at least a pair of support bases provided on the mounting tool. Each of the at least a pair of support bases is positioned adjacent a respect edge of the turbine component when the turbine component is retained in the mounting tool. Each of the at least a pair of support bases is configured for additively building a sacrificial support on each of the at least a pair of support bases for enabling repair of the turbine component.