Aircraft Engine Feature Machining with Corrected Tool Paths

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Solution Overview

Problem

Existing machining processes for aircraft engine components, such as spline couplings, often result in manufacturing discrepancies due to variances between the expected and actual positions of the cutting tool, leading to precision issues and inefficiencies.

Innovation Solution

A method and system for manufacturing aircraft engine components that involves machining a semi-finished shape, determining the actual position of target points on the surface, computing the difference between actual and nominal positions, and using this information to correct the cutting tool's position and define a corrected tool path for achieving the final shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a rotating cutting tool is used to machine spline teeth and grooves, then the machining process can be completed, but variances between expected and actual tool positions result in manufacturing discrepancies

Engineering Contradiction:

Improvemachining efficiencyVSAvoidspline feature precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by first machining a semi-finished shape of the spline features, then measuring the actual positions of target points on this semi-finished surface before completing the final machining. This preliminary measurement and correction step allows the final machining to compensate for any position variances, thereby achieving high precision without sacrificing productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by measuring the actual positions of target points on the semi-finished spline features and using this measurement information to compute corrections for the final machining operation. The measured deviations are fed back into the machining system to adjust the tool path, ensuring that the final dimensions meet precision requirements despite initial positioning variances

Inventive Principle:

Principle #23Feedback

2Ease of manufacture

If the cutting tool position is not corrected, then the machining process is simple, but manufacturing discrepancies occur

Engineering Contradiction:

Improvemachining process simplicityVSAvoidfeature dimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces an intermediary measurement and computation step between the semi-finished machining and final machining operations. Target points are measured on the semi-finished surface, and correction values are computed based on these measurements. This intermediary process acts as a mediator that translates physical measurements into machining corrections, maintaining both ease of manufacture and high precision

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12346091B2Method of manufacturing a part of an aircraft engine

Publication Date: 2025.07.01 PRATT & WHITNEY CANADA CORP

AI summary

A method of manufacturing a feature in a part with a cutting tool, includes machining a semi-finished shape of the feature, determining an actual position of at least one target point on a surface of the semi-finished shape, and computing a difference between the determined position of the at least one target point and a nominal position of the at least one target point on a digitized model of the part having the semi-finished shape of the feature. As a function of the difference, a correction to a position of the cutting tool on a nominal tool path to achieve the final shape of the feature from the semi-finished shape is determined, and the correction is used to define a corrected tool path. The finished shape of the feature is then machined with the cutting tool by moving the cutting tool along the corrected tool path.