Flexible Fork Deep Rolling Tool for Turbine Blade Fatigue
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Solution Overview
Problem
Conventional deep rolling tools are bulky, slow, and expensive due to their hydraulic systems and limited adjustability, making them inefficient for processing components with complex geometries.
Innovation Solution
A deep rolling tool with a flexible fork structure and crowned rollers, which applies compressive stress without the need for hydraulic systems, allowing for adjustable force distribution and improved contact zones, enabling faster processing and increased fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic ball bearing clamping elements are used to apply compressive stress, then the tool can provide sufficient clamping force, but the tool becomes bulky and slow due to rigid structure and small contact zone
Solution Approach 1:
The tool divides the contact zone into multiple rolling elements (balls or rollers) distributed across the surface, allowing simultaneous contact with multiple points on the component. This segmentation increases the effective contact area while maintaining compact tool structure, enabling faster processing without sacrificing clamping force capability
Solution Approach 2:
The invention uses spherical ball bearings or curved rollers instead of flat clamping surfaces. The curved geometry of the rolling elements creates larger contact zones with the component surface, increasing processing speed while the rolling motion provides sufficient compressive force for deep rolling operations
2Force
If hydraulic systems are used to actuate clamping elements, then sufficient force can be applied, but the tool complexity and cost increase due to high pressure pump requirements
Solution Approach 1:
The invention extracts and eliminates the hydraulic system entirely from the tool design. Instead of using hydraulic actuators to apply force, the tool relies on the mechanical properties of the flexible fork structure and the rolling motion of the elements to generate and maintain compressive force, significantly reducing complexity and cost
Solution Approach 2:
The flexible fork structure automatically generates the necessary clamping force through its elastic deformation when the rolling elements contact the component. The system is self-regulating, requiring no external hydraulic power source or active control system to maintain the compressive force during operation
3Stability of the object's composition
If conventional rigid tools are used for deep rolling, then structural stability is maintained, but adaptability to different component geometries and thicknesses is limited
Solution Approach 1:
The tool employs a flexible fork structure that can dynamically adjust its shape and configuration based on the component geometry being processed. The flexibility allows the tool to adapt to different thicknesses and contours while the rolling elements maintain stable contact and apply consistent compressive force, achieving both adaptability and operational stability
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
The solution significantly improves processing speed and reduces costs by providing a more compact and adjustable tool that enhances fatigue life and surface finish of components like turbine blades, with preliminary testing showing greater than 10 times improvement in fatigue life.
Implementation Method 1
the rolling elements are configured to apply a compressive stress to articles received by the deep rolling tool
Implementation Method 2
A deep rolling tool with a flexible fork structure and crowned rollers
Data Source
AI summary
A device and methods are provided for deep rolling. In one embodiment, a machine includes a deep rolling tool having a plurality of rolling elements, wherein each rolling element is mounted at the distal end of a fork arm, and wherein the rolling elements are configured to apply a compressive stress to articles received by the deep rolling tool. The machine may also include a positioning element coupled to the deep rolling tool, wherein the positioning element is configured to position the deep rolling tool and apply the deep rolling tool to an article.