Offset Roller Tool for Deep Rolling Complex Blade Roots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing deep rolling tools for fan blades are expensive, complex, and inefficient due to the need for hydraulic pressure maintenance and small surface area contact, which slows production and cannot be easily integrated with standard machine tools.
Innovation Solution
A system for deep rolling fan blades using a roller tool with an adaptor plate, an arm with an offset to prevent contact, a roller disk, and a fixture to support the fan blade, allowing for controlled contact stress and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydraulic burnishing tools with ball bearing are used for complex geometries, then processing precision is improved, but device complexity and cost increase due to hydraulic pressure maintenance requirements
Solution Approach 1:
The patent extracts and eliminates the hydraulic pressure maintenance system from the deep rolling tool, replacing it with a simpler mechanical loading mechanism. The tool shaft is directly loaded through the robot arm without requiring hydraulic actuators, thereby removing the complex hydraulic pressure control system while maintaining processing precision.
Solution Approach 2:
The patent makes the deep rolling tool compatible with widely available robot arms and machine tools by universalizing the interface and control mechanism. The tool can be integrated with standard robotic systems without requiring specialized hydraulic infrastructure, enabling multi-functionality across different manufacturing platforms.
2Manufacturing precision
If hydraulic burnishing tools with ball bearing are used, then processing precision is improved, but production time increases due to small surface area contact
Solution Approach 1:
The patent changes the contact geometry parameter from a small ball bearing surface to a larger roller surface. This parameter change increases the contact area between the tool and workpiece, allowing for faster material processing while maintaining the precision needed for complex blade geometries.
3Manufacturing precision
If hydraulic burnishing tools are used, then processing precision is improved, but ease of operation deteriorates due to constant hydraulic pressure adjustment requirements
Solution Approach 1:
The patent implements self-service by enabling the robot arm's existing control system to directly control the deep rolling tool without requiring separate hydraulic pressure control mechanisms. The tool automatically receives loading commands through the robot's standard interface, eliminating manual hydraulic pressure adjustments.
4Reliability
If offset is formed in the arm to prevent contact, then collision avoidance is improved, but device complexity increases
Solution Approach 1:
The patent introduces asymmetry by forming an offset in the arm geometry. This asymmetric design positions the roller at a distance from the arm's centerline, creating built-in clearance that prevents collision with the blade root during processing. The offset is a simple geometric modification rather than a complex mechanical addition.
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 system effectively induces high compressive stresses up to 1.5 mm depth, improving fatigue life and damage tolerance, while reducing production time and costs by simplifying the process and integrating with standard machine tools.
Implementation Method 1
A dry deep rolling process, which can induce high compressive stresses up to 1.5 mm depth from the surface of a material through localized plastic deformation
Implementation Method 2
The Deep Rolling process uses a roller to roll the surface under controlled load & speed. The rolling pressure induces a deep layer of compressive residual stress.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system for deep rolling a workpiece including a roller tool comprising an adaptor plate proximate an adapter end; an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the workpiece; a roller disk joined to the roller end, the roller disk configured to contact the workpiece; and a fixture supporting the workpiece.