Portable Field Drill for Superalloy Turbine Rotor Disk Cooling Holes
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Solution Overview
Problem
Modern turbine rotor disks made from superalloys are expensive and difficult to machine, requiring specialized equipment and skilled labor, which complicates the process of adding or modifying cooling holes in the field.
Innovation Solution
A portable system comprising a stand, drill with self-feeding spindle, nose piece alignment bushing, and drill guide that automatically drills predetermined depths through superalloys, ensuring precise alignment and operation without the need for heavy CNC machines, using standard shop air as a power source and minimal technical support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used on superalloy turbine rotor disks, then manufacturing precision can be achieved, but device complexity and cost increase significantly due to requiring heavy CNC machines and specialized equipment
Solution Approach 1:
The system divides the drilling operation into distinct functional components: a portable drill unit with self-feeding spindle, a separate drill guide for positioning, and a stand for support. This segmentation allows each component to be optimized independently and reduces the overall complexity compared to a single heavy CNC machine while maintaining drilling precision through coordinated operation of the segmented parts.
Solution Approach 2:
The drill guide acts as an intermediary between the portable drill unit and the turbine rotor disk. It provides precise positioning and alignment for the drill bit without requiring the drill itself to be a complex CNC machine. The drill guide mediates the positioning function, allowing the drill unit to remain simple and portable while still achieving accurate drilling results.
2Manufacturing precision
If traditional machining methods are used on superalloy turbine rotor disks, then manufacturing precision can be achieved, but the process becomes time-consuming and requires specialized skilled labor
Solution Approach 1:
The drill incorporates a self-feeding spindle mechanism that automatically controls the feed rate and depth of drilling without requiring constant operator intervention or specialized skill. The system serves itself by automatically regulating the drilling process, reducing the time needed for skilled labor setup and monitoring while maintaining precision through the self-regulating mechanism.
Solution Approach 2:
The drill guide is pre-configured with alignment features and positioning mechanisms that establish the correct drill path before drilling begins. This preliminary setup eliminates the need for time-consuming measurements and adjustments during the actual drilling operation, reducing overall modification time while ensuring precision is achieved from the start.
3Manufacturing precision
If heavy CNC machines are used for drilling cooling holes, then manufacturing precision is maintained, but ease of operation in field conditions deteriorates due to portability constraints
Solution Approach 1:
The system segments the heavy CNC machining function into a portable drill unit combined with a separate drill guide and stand. This allows the drilling operation to be performed in the field without transporting heavy CNC equipment, as the segmented components can be easily moved and assembled on-site while still achieving precision through the coordinated system.
Solution Approach 2:
The drill guide serves as a portable intermediary that provides CNC-level positioning accuracy without requiring a heavy CNC machine. It mediates between the simple portable drill and the workpiece, delivering alignment precision through its dedicated positioning features while maintaining ease of field operation due to its compact, standalone design.
4Productivity
If automated drilling is implemented, then productivity increases, but device complexity increases due to requiring self-feeding spindles and control systems
Solution Approach 1:
The self-feeding spindle is designed to automatically regulate its own feed rate and drilling depth without requiring external control systems or complex automation. The spindle mechanism incorporates inherent self-regulating features that allow it to feed automatically into the workpiece and stop at the predetermined depth, increasing productivity through automation while keeping the device complexity manageable through self-service design.
Data Source
AI summary
A system and method for modifying a gas turbine engine in the field to drill a series of cooling holes in a turbine rotor disk made of a superalloy. A portable field repair system includes a stand configured to receive, support, and position a turbine rotor disk, a drill having a self-feeding spindle and configured to automatically drill a predetermined depth through a superalloy and to automatically stop upon completion, a drill guide configured to coordinate the drill with a plurality of radial axes associated with a precise hole pattern to be cut and a drill mount configured to mechanically couple the drill to the drill guide and to position the drill during the modification of the gas turbine engine turbine rotor disk.