Multi-Station EDM Fixture for Horizontal Vane Slot Repair
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Solution Overview
Problem
Existing EDM processes for turbine and compressor vane repair are difficult to automate due to the need for precision and accuracy, especially when changing slot lengths, and require parts to be held in a vertical orientation, leading to inconsistencies and manual resetting.
Innovation Solution
A fixture that secures parts in a horizontal orientation, using a support structure with clamps and a clocking tab for consistent positioning, and incorporates an electrode holder with locating structures and computer software for automated EDM processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If parts are held in vertical orientation for EDM processing, then workspace constraints are addressed, but the part must be reset for leading and trailing edge repair reducing productivity
Solution Approach 1:
The fixture transitions the part orientation from vertical to horizontal, changing the spatial dimension of operation. This allows the electrode holder to access both leading and trailing edges of the vane simultaneously in the same horizontal plane, eliminating the need for resetting and enabling continuous automated processing.
2Adaptability or versatility
If manual processes are used for vane slot repair, then flexibility is maintained, but inconsistencies and lack of repeatability occur worsening manufacturing precision
Solution Approach 1:
The system replaces manual mechanical positioning and operation with an automated electrode holder system guided by computer software. The software identifies slot locations and controls the EDM operation, ensuring consistent and repeatable processing while maintaining the ability to handle different vane configurations.
Solution Approach 2:
The computer software provides feedback by identifying the location of slots to be processed and confirming proper fixture and part positioning. This closed-loop control ensures manufacturing precision by verifying setup accuracy before and during the EDM operation.
3Ease of manufacture
If existing EDM fixtures are used, then simple clamping is provided, but automated control and locating accuracy are insufficient
Solution Approach 1:
A shim is introduced as an intermediary component that fits into the seal slot to identify the center location with high precision. This simple yet effective locating structure enables accurate electrode positioning without complicating the overall fixture design, bridging the gap between simplicity and precision.
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
Enables repeatable and reproducible EDM processing, automating the repair process and reducing human error by ensuring accurate and efficient access to both leading and trailing edge slots without manual repositioning.
Implementation Method 1
EDM is a machining process that removes material from a workpiece using thermal energy generated by electrical discharges (sparks)
Implementation Method 2
thermal energy generated by electrical discharges (sparks)
Data Source
AI summary
An electrical discharge machining (EDM) fixture for machining a part includes a support structure fixable onto a work surface, a base plate fixed to the support structure, a toggle clamp positioned on one side of the base plate, and a secondary clamp positioned on an opposite side of the base plate. A plurality of contact points are respectively associated with the toggle clamp and the secondary clamp, and a tool ball is fixed to the base plate.