Laser-Shaped Cooling Hole Drilling Using Teardrop Energy Profiles
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Solution Overview
Problem
The high cost of machining processes for producing shaped cooling holes in gas turbine engine components limits their use, as they are more expensive than laser hole drilling, which typically only creates straight holes.
Innovation Solution
A laser hole drilling system that uses a spherical lens and a control system to generate an asymmetric teardrop-shaped energy distribution at a focal plane, allowing for the creation of shaped cooling holes by positioning the lens according to polar coordinates of the Fourier Transform of a laser plane, enabling the drilling of complex shapes like teardrop holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If machining processes such as EDM are used to produce shaped cooling holes, then the cooling system design flexibility is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces mechanical machining processes (EDM) with a laser-based optical system. The laser drilling apparatus uses a controlled laser beam to create shaped cooling holes, eliminating the need for expensive mechanical machining while maintaining design flexibility. This substitution of mechanical systems with optical/thermal systems resolves the contradiction between design versatility and manufacturing cost.
Solution Approach 2:
The patent employs parameter changes by controlling laser beam parameters (intensity, duration, focal position) to create different cooling hole shapes. By varying these parameters, the system can produce various shaped cooling holes (circular, teardrop, elongated) without changing the physical machining tool, thereby maintaining design flexibility while reducing manufacturing costs compared to mechanical processes.
2Ease of manufacture
If laser hole drilling is used to create cooling holes, then the manufacturing cost is reduced, but the ability to create shaped cooling holes is limited
Solution Approach 1:
The patent introduces dynamics by making the laser beam controllable in real-time. The laser parameters (intensity, pulse duration, focal position, scan speed) can be dynamically adjusted during the drilling process to create different cooling hole shapes. This dynamic control capability enables the laser system to produce shaped cooling holes that previously required mechanical machining, thereby maintaining low cost while improving shape capability.
Solution Approach 2:
The patent uses parameter changes to enable shape control. By varying laser parameters such as beam intensity distribution, focal position, and exposure time, the system can create different cooling hole geometries (circular, teardrop, elongated) while maintaining the cost advantages of laser drilling over mechanical processes.
3Productivity
If traditional laser drilling is used, then the process is simple and fast, but the cooling holes are limited to straight cylindrical shapes
Solution Approach 1:
The patent applies dynamics by implementing real-time control of laser parameters during the drilling process. The laser beam intensity, focal position, and scan path can be dynamically adjusted to create shaped cooling holes while maintaining high drilling speeds. This dynamic control allows the system to produce complex geometries without sacrificing the productivity advantages of laser drilling.
Solution Approach 2:
The patent employs parameter changes to transform the laser drilling process from creating simple cylindrical holes to shaped cooling holes. By modifying parameters such as beam intensity distribution, focal position, and exposure duration, the system can generate various cooling hole geometries while maintaining the speed and efficiency of laser-based processing.
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 method allows for the cost-effective production of asymmetric teardrop-shaped cooling holes in gas turbine components, reducing manufacturing costs and enabling the design of more complex cooling systems without the need for expensive machining processes.
Implementation Method 1
A laser hole drilling system according to one disclosed non-limiting embodiment of the present disclosure includes a laser source that generates a laser beam along an optical axis; a spherical lens along the optical axis downstream of the laser source
Implementation Method 2
laser hole drilling is performed by focusing a laser (typically 1026 nm) onto the gas turbine component
Data Source
AI summary
A laser hole drilling system includes a laser source that generates a laser beam along an optical axis; a spherical lens along the optical axis downstream of the laser source; and a control system in communication with the spherical lens and the laser source, the control system operable to locate the spherical lens with respect to the laser source to produce a light distribution in polar coordinates of a real portion of the Fourier Transform to generate an asymmetric teardrop shaped energy distribution at a focal plane.