Orifice Diameter Correction via Perimeter Peening
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Solution Overview
Problem
Machining of refractory alloy orifices often results in excessive diameters, leading to parts being scrapped due to uncorrectable tolerance issues, particularly in gas turbine components where permeability is critical and difficult to adjust.
Innovation Solution
A method involving caulking the periphery of the orifice using a tool with a spherical or frustoconical contact end to reduce the diameter by pushing material inward, allowing for precise diameter reduction while maintaining the initial shape and minimizing surface impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to create orifices in refractory alloy parts, then the parts can be manufactured with required geometry, but the diameter tolerance cannot be maintained and parts are scrapped when diameter exceeds specifications
Solution Approach 1:
The caulking process is applied after machining to pre-correct the orifice diameter before final assembly. By pushing material inward during caulking, the diameter is reduced to within tolerance specifications, preventing scrap of parts that initially exceeded maximum diameter limits
Solution Approach 2:
The mechanical properties of the refractory alloy are temporarily altered through plastic deformation during caulking. The material yields under controlled pressure to reduce orifice diameter, then stabilizes at the new dimension, achieving precise diameter control without scrapping the part
2Temperature
If refractory alloy is used for high-temperature gas turbine components, then the parts can withstand extreme temperatures, but machining difficulties increase and production costs rise
Solution Approach 1:
Instead of relying solely on complex machining operations to achieve precise orifice dimensions in difficult-to-machine refractory alloys, the invention substitutes a simpler mechanical caulking process. This post-machining operation corrects diameter deviations without requiring re-machining, significantly reducing manufacturing complexity and cost while maintaining the heat-resistant properties of the alloy
3Manufacturing precision
If a spherical ball is used for caulking, then significant diameter reduction is achieved with minimal surface impact, but the tool complexity increases
Solution Approach 1:
The caulking tool employs a spherical ball contact surface instead of flat or angular surfaces. The curved geometry of the sphere distributes pressure evenly around the orifice perimeter, achieving uniform diameter reduction while minimizing localized surface deformation. This simple geometric choice effectively corrects diameter deviations without requiring complex tool mechanisms
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 the recovery of parts that would otherwise be scrapped by correcting excessive diameters and permeability issues, reducing production costs and scrap rates in high-value refractory alloy components like those in gas turbines.
Implementation Method 1
A metallic material has a certain malleability allowing, within certain limits, the plastic deformation of the perimeter of the orifice
Data Source
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AI summary
The invention relates to a method for reducing the diameter of an opening (2), comprising a step of peening a perimeter (3) of the opening (2). The invention also relates to a method for correcting the permeability of a part (9, 10) comprising a plurality of openings (2) for allowing a gaseous fluid to pass therethrough. The method is characterised in that it comprises the steps of identifying at least one opening (2) with a diameter Dr which exceeds a predetermined upper limit Dmax and reducing said excessive diameter Dr by peening a perimeter of the opening (2).