Turbomachine Liner Cooling Hole Machining Around Raised Ribs
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Solution Overview
Problem
Current machining processes for turbomachine liners with cooling holes often weaken the components, particularly when positioning these holes near raised ribs, due to complex and laborious methods that fail to effectively avoid damaging the structural integrity.
Innovation Solution
A method utilizing a 3D scanning and multi-axis machining apparatus to precisely position and drill cooling holes within turbomachine liners, ensuring they are spaced away from ribs to prevent laser backstrike damage and maintain structural integrity, employing a laser drill and 3D scanner to create a surface map and guide the drilling device to avoid intersecting ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling holes are positioned near ribs in the liner, then the cooling coverage is improved, but the structural integrity of the liner is weakened due to laser backstrike damage
Solution Approach 1:
The patent applies preliminary action by scanning the liner surface with a 3D scanner before machining to create a digital map of the surface topology, including the locations of ribs. This advance knowledge allows the machining system to plan cooling hole positions that avoid ribs, preventing laser backstrike damage while maintaining adequate cooling coverage.
Solution Approach 2:
The patent replaces traditional mechanical probing and manual positioning methods with a 3D scanning system that uses optical or laser-based measurement. This substitution enables precise identification of rib locations and facilitates automated positioning of cooling holes away from ribs, eliminating the need for complex mechanical avoidance procedures.
2Strength
If complex processes are used to avoid positioning cooling holes near ribs, then the structural integrity is maintained, but the machining process becomes laborious and time-consuming
Solution Approach 1:
The patent applies self-service by enabling the machining system to automatically identify rib locations through 3D scanning and autonomously determine optimal cooling hole positions that avoid ribs. The system uses its own scanning data to guide the machining process, eliminating the need for external manual intervention or complex pre-planning procedures.
Solution Approach 2:
The patent changes the operational parameters of the machining process by transitioning from fixed, pre-determined hole positions to dynamically adjusted positions based on real-time 3D surface mapping. This allows the system to adapt cooling hole locations to the actual liner geometry, maintaining structural integrity while streamlining the machining workflow.
3Ease of manufacture
If traditional machining methods are used without 3D scanning, then the process is simpler in setup, but cooling holes may be positioned incorrectly causing laser backstrike damage
Solution Approach 1:
The patent applies feedback by using the 3D scanner to continuously monitor and map the liner surface geometry before and during the machining process. This real-time feedback allows the system to verify rib locations and adjust cooling hole positions accordingly, ensuring accurate positioning while maintaining relatively simple setup procedures through automated guidance.
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 enhances the structural integrity of turbomachine liners by accurately placing cooling holes without weakening the ribs, reducing the risk of laser-induced damage and simplifying the machining process, thereby improving the durability and efficiency of the manufacturing method.
Implementation Method 1
scanning a first surface of a component with a three-dimensional (3D) scanner to determine a location of a raised feature of the component
Implementation Method 2
The cooling holes are machined in the liners using a laser drill, for example
Data Source
Figure 1
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Figure 4~7
AI summary
An component manufacturing method includes scanning a first surface (58) of a component (50) to determine a location of pocket surfaces (78) of the first surface (58). The method machines apertures (62) in the component (50) from a second, opposite surface (56) of the component (50). The apertures (62) each have a cooling air inlet (64) within one of the pocket surfaces (78) and a cooling air outlet (66) within the second surface (56).