Flexible Fork Peening Tool Path for Turbo Machinery Blades
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Solution Overview
Problem
Current methods for determining tool paths for flexible fork peening tools are inefficient in approximating complex three-dimensional surfaces of turbo machinery blades, leading to suboptimal peening processes that do not effectively induce compressive stresses and strain hardening.
Innovation Solution
A computer-based system defines and synthesizes tool paths by creating curve boundaries, drive surfaces, and converting zigzag motions to pinching motions, ensuring a one-to-one correspondence between the tool paths on both sides of the airfoil surface, while constraining the flexible fork peening tool to minimize rotation and vibration, using a CNC machine with 5-axis or more degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tool path methods are used for flexible fork peening, then the peening process can be performed, but the approximation of complex three-dimensional surfaces is inefficient and suboptimal
Solution Approach 1:
The complex three-dimensional surface of the airfoil is segmented into multiple discrete points along the tool path. The system defines specific points along the airfoil surface and calculates tool positions at these discrete locations, transforming a continuous complex surface approximation problem into a series of manageable discrete point calculations.
Solution Approach 2:
The patent introduces a new computational dimension by creating drive surfaces and using mathematical modeling to define tool paths in three-dimensional space. The system uses coordinates (x, y, z) and rotational angles to precisely position the tool, adding dimensional complexity to achieve better surface approximation accuracy.
2Adaptability or versatility
If the flexible fork peening tool is allowed to rotate freely, then the tool can adapt to surface variations, but twisting and vibration increase
Solution Approach 1:
The patent applies different constraints to different aspects of tool motion. The tool is constrained from rotating about its vertical axis (restricting unwanted twisting), while still allowing controlled movement in other degrees of freedom through the five-axis CNC system to maintain contact with the airfoil surface.
Solution Approach 2:
The system changes the operational parameters of the tool by defining specific rotational constraints (constraining rotation about the vertical axis) while maintaining five degrees of freedom for controlled movement. This parameter adjustment stabilizes the tool during peening while preserving necessary adaptability.
3Manufacturing precision
If a five-axis or more CNC machine is used, then tool path precision is improved, but device complexity increases
Solution Approach 1:
The five-axis CNC machine performs multiple functions: it controls the tool's position in three-dimensional space, manages rotational movements, maintains constrained orientation, and executes the peening process. This multi-functionality justifies the increased device complexity by consolidating multiple control requirements into a single integrated 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 peening operations that minimize twisting and vibration, ensuring consistent peen depth and effective strain hardening of blade edges, improving material properties and reducing operational complexities.
Implementation Method 1
Peening may also induce strain hardening in the surface of the metal being worked (e.g., a blade edge)
Data Source
AI summary
Systems and method for tool path approximation may comprise approximating the outer surface of a part to be worked. The outer surface may be approximated by a plurality of airfoils. Moreover, the system and methods approximate a tool path based on a cutting tool and convert the tool path to accommodate a non-cutting processing tool. The tool path may be implemented on a computer numerically controlled machine that is configured to control a flexible fork peening tool.