Aircraft Engine Feature Machining With Angular Alignment Correction

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Solution Overview

Problem

Existing machining processes for aircraft engine components, such as firtree slots and teeth, face challenges due to misalignment between the wire and the component during wire electrical discharge machining (WEDM), leading to unsuitable feature angles and non-uniform radial depths.

Innovation Solution

A method and system for machining features in aircraft engine components using a cutting machine with a support rotatable about a rotation axis, where the component is mounted for rotation about its central axis. The method involves determining the coordinates of at least three points on a reference surface, calculating an angular correction for the cutting tool, and machining the feature with the tool angled accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If expensive fixture systems with tight tolerances are used to mount the component, then manufacturing precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoidfixture system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical fixture systems with tight tolerances by introducing a measurement and calculation system. A probe measures coordinates of reference points on the component, and a processor calculates the actual orientation of the reference surface. This computational approach substitutes for expensive mechanical alignment fixtures, achieving the same alignment precision through software-based correction of the cutting tool orientation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional WEDM is used without alignment correction, then device complexity is reduced, but manufacturing precision deteriorates due to wire-component misalignment

Engineering Contradiction:

Improvefeature angle precisionVSAvoidmachining process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements a feedback mechanism where the probe measures the actual coordinates of reference points on the component, providing information about the component's orientation. The processor uses this feedback to calculate the actual orientation of the reference surface and determine the angular correction needed. This closed-loop feedback system compensates for misalignment between the wire and component, improving feature angle precision without requiring complex mechanical alignment fixtures.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the operational parameters of the machining process by dynamically adjusting the cutting tool orientation based on measured coordinates. Instead of maintaining fixed mechanical alignment, the system calculates and applies angular corrections to the cutting tool based on the actual measured orientation of the component. This parameter adjustment approach improves manufacturing precision while keeping the overall device complexity manageable.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If calibration inaccuracies are present in the machining system, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improveradial depth uniformityVSAvoidcalibration system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex calibration systems by using a probe to directly measure the actual coordinates of reference points on the component. Instead of relying on pre-calibrated mechanical fixtures, the system measures the actual orientation of the reference surface and calculates the necessary corrections. This measurement-based approach compensates for calibration inaccuracies in the machining system, ensuring uniform radial depth without requiring elaborate calibration procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for precise machining of features without the need for expensive fixture systems with tight tolerances, optimizing part alignment, reducing calibration inaccuracies, and ensuring uniform feature dimensions.

Implementation Method 1

determining coordinates of at least three points on a reference surface of the component

Methodology Applied

Scientific EffectPosition sensing:

Implementation Method 2

Wire electrical discharge machining (WEDM) is a process by which a wire is fed through a component to be machined

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Data Source

PatentUS12276962B2Method of machining a feature in an aircraft engine component

Publication Date: 2025.04.15 PRATT & WHITNEY CANADA CORP

AI summary

A method of machining a feature in a component using a machine having a support rotatable about a rotation axis and having a cutting tool movable relative to the component, the component being mounted on the support for rotation about a central axis of the component, the method includes: determining coordinates of at least three points on a reference surface of the component, the at least three points being circumferentially offset from one another relative to the central axis; determining an angular correction to apply to the cutting tool based on the coordinates of the at least three points; and machining the feature in the component using the cutting tool angled with the angular correction.