Jet Engine Rotor Blade Burnishing Tool with Aligned Spindle Axis
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Solution Overview
Problem
Existing rolling tool devices for deep rolling blade elements in jet engine rotors are complex to program and implement in multi-axis machining centers due to axis offsets during machining of free-form surfaces, increasing production costs.
Innovation Solution
A machine tool with a rolling tool device where the carrier spindle axis aligns with the rolling regions, allowing for zero distance between them, enabling constant vector management and reducing deformation, with rotatable tong bodies and a drive device for adjustable engagement, and adapter elements for varying radial depths and forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rolling tool devices are used with offset axes, then the rolling function is achieved, but programming complexity and manufacturing costs increase significantly
Solution Approach 1:
Instead of having the spindle axis offset from the contact point (conventional design), the invention inverts the configuration by aligning the spindle axis directly through the contact point between the rolling areas. This inversion eliminates the need for complex vector calculations and constantly changing coordinates during programming, significantly simplifying the manufacturing process while maintaining the rolling function.
Solution Approach 2:
The aligned axis configuration creates a universal reference frame that works for all machining operations with this tool device. The single, fixed axis alignment provides a consistent reference for programming various machining operations, making the system universally applicable without requiring operation-specific complex calculations.
2Device complexity
If the distance between rolling areas is reduced to zero, then programming is simplified, but deformation of thin-walled components may occur
Solution Approach 1:
The invention makes the distance between rolling areas dynamically adjustable rather than fixed. The gripper bodies can rotate relative to each other about a common pivot bearing, allowing the rolling areas to be positioned at any distance from each other. This dynamic adjustment enables the system to adapt to different workpiece geometries and thicknesses, preventing deformation of thin-walled components while maintaining the simplified axis alignment for programming.
3Adaptability or versatility
If gripper bodies are made rotatable about common pivot bearing, then access to clearance profiles is improved, but control complexity increases
Solution Approach 1:
The gripper bodies are coupled to each other via a drive device that automatically coordinates their rotational movement. When one gripper body rotates about the common pivot bearing, the coupling mechanism ensures the other gripper body rotates in a coordinated manner to maintain the desired distance between rolling areas. This self-service mechanism eliminates the need for complex external control systems while providing versatile access to clearance profiles.
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
Simplifies programming and implementation in multi-axis machining centers, reduces deformation, and allows for high surface quality with controlled rolling forces, enhancing durability and fatigue strength of blade elements.
Implementation Method 1
Blade elements are further hardened via the rolling tool devices by axial engagement starting from the blade leading edge through machining in the flow direction by means of hard rolling, in order to increase the resistance of the blade elements to foreign body damage and also vibration loads
Data Source
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AI summary
The invention relates to a deep-rolling tool device (14) for deep-rolling especially blade elements of a rotor portion of a jet engine, comprising a tool support (15). Said tool support (15) can be connected to a support spindle (16). Two tong elements (17, 18) are rotatably connected to the tool support (15). Said tong elements (17, 18) have respective rolling portions (21, 22), a distance between the rolling portions being variable subject to a rotational movement of the tong elements (17, 18). According to the invention, an axis (39) of the support spindle (16) runs between the rolling portions (21, 22) through a point of contact between the rolling portions (21, 22) when the support spindle is connected to the tool support (15), which contact is established when the distance between the rolling portions (21, 22) equals zero.