Rotating Attrition Liner Machining Tool for Gas Turbine Engines
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Solution Overview
Problem
Existing machining tools for attrition liners in gas turbine engines are either labor-intensive, pose health and safety risks, require skilled operators, or are large and expensive, making them unsuitable for efficient and safe use in various scenarios, especially when replacing single sections or entire liners.
Innovation Solution
A rotating attrition liner machining tool with a connector and cutter that attaches to the gas turbine engine's fan blade mount, featuring a counter-weight for balance, radial and axial adjustment mechanisms, and a motor system for precise machining, allowing for manual or motorized operation and efficient debris extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a hand-held machining tool is used to machine the attrition liner, then the machining can be performed with simple equipment, but the process produces a large amount of dust that poses health and safety risks and requires a highly skilled operator
Solution Approach 1:
A water delivery system is introduced as an intermediary between the cutter and the attrition liner. The water suppresses dust generation during machining by wetting the cutting zone, thereby eliminating the harmful dust effect while maintaining the simplicity of hand-held tool operation
Solution Approach 2:
The operator directly controls the machining process with the hand-held tool, performing both the cutting and dust suppression functions through a single integrated operation. The water delivery system is activated by the operator during the machining process, allowing self-service dust control without requiring additional specialized equipment or personnel
2Device complexity
If a hand-held machining tool is used to machine the attrition liner, then the equipment can be simple and portable, but the operator must be in an uncomfortable position for extended periods which reduces ease of operation
Solution Approach 1:
The machining system is segmented into a portable hand-held cutting unit that the operator can maneuver freely, separate from the fixed water delivery infrastructure. This allows the operator to maintain an ergonomic position while the water system remains stationary, improving ease of operation without requiring complex integrated machinery
3Manufacturing precision
If dedicated tooling is provided to machine the entire attrition liner, then the machining precision and efficiency are improved, but the equipment becomes very large and expensive requiring a floor-standing arrangement
Solution Approach 1:
The hand-held machining tool is designed to be universally applicable for machining attrition liners, combining the precision of dedicated tooling with the portability of manual equipment. The tool can be used on entire liners or individual sections, eliminating the need for large floor-standing equipment while maintaining manufacturing precision through skilled operator control and water-cooled cutting
4Stability of the object's composition
If dedicated tooling is centralized on the low pressure compressor shaft, then the machining can be performed with stable equipment, but the low pressure compressor disk must be removed which creates corrosion risk
Solution Approach 1:
The hand-held machining tool acts as an intermediary that eliminates the need to remove the low pressure compressor disk. By using a portable tool that can be maneuvered around the engine, the stable mating faces remain assembled, preventing corrosion while still enabling precise machining of the attrition liner through controlled manual operation
Data Source
AI summary
An attrition liner machining tool, configured to machine the surface of an attrition liner provided radially outward of a set of a plurality of fan blades in a gas turbine engine. The tool includes at least one rotating machine tool having a connector at a first end and a cutter at a second end. The connector is configured to rigidly connect to a rotating fan blade mount of the gas turbine engine that, in use of the gas turbine engine, supports the fan blades. The cutter is configured to machine the attrition liner. The at least one rotating machine tool is configured such that, when it is connected to said rotating fan blade mount of a gas turbine engine, the cutter is passed across the surface of the attrition liner when said rotating fan blade mount is rotated.