Rotor Disk Groove Machining With Alternating Supported Positions

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Solution Overview

Problem

The existing methods for producing rotor disks with profile grooves in turbomachines face challenges in maintaining stability and preventing deformation during machining, especially when introducing profile grooves that require significant material removal, leading to potential mechanical burdens and economic inefficiencies.

Innovation Solution

The method involves introducing first and second profile grooves in alternating positions, with the second grooves being supported by the inner wall surfaces of the first grooves, allowing for stable material removal and extended tool life through the use of inserts or filling materials to provide support and reduce deformation risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If profile grooves are machined in close succession without intermediate positions, then manufacturing productivity is improved, but disk deformation increases due to insufficient material support

Engineering Contradiction:

Improvemanufacturing productivityVSAvoiddisk stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The machining process is segmented into multiple passes with alternating groove positions. First grooves are machined at certain circumferential positions, then second grooves are machined at intermediate positions between the first grooves. This segmentation allows the disk to maintain sufficient material support between grooves during machining, preventing deformation while enabling high-density groove patterns.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first profile grooves are machined in advance at specific circumferential positions before machining the second grooves. These preliminary grooves serve as reference features and provide structural support during subsequent machining operations. The alternating pattern ensures that when second grooves are machined, the first grooves remain intact to support the disk structure.

Inventive Principle:

Principle #10Preliminary action

2Shape

If significant material is removed to create profile grooves, then the desired geometric shape is achieved, but mechanical strength decreases due to weakened disk structure

Engineering Contradiction:

Improveprofile groove geometryVSAvoiddisk strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

Material removal is segmented into multiple sequential operations targeting different circumferential positions. By removing material at first positions, then at intermediate second positions, the disk structure retains sufficient bridging material between grooves. This prevents excessive weakening that would occur if all grooves were machined simultaneously or in close succession.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The machining process applies different operations to different local regions of the disk. First grooves are machined at specific locations, then second grooves are machined at intermediate locations. This local quality approach ensures that each machining operation works on a locally supported structure, maintaining overall disk strength while achieving the required groove geometry.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If profile grooves are machined with high precision requirements, then manufacturing precision is improved, but tool life decreases due to increased mechanical stress on cutting tools

Engineering Contradiction:

Improvegroove precisionVSAvoidtool life

Core Design Contradiction:

Manufacturing precisionVSDuration of action of moving object

Solution Approach 1:

The precision machining task is divided into multiple passes machining grooves at alternating positions. This segmentation reduces the mechanical stress on any single cutting tool pass, as the disk structure remains better supported between operations. Consequently, tool life is extended while maintaining the ability to achieve high precision groove geometries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Preliminary grooves are machined first to establish reference geometry and provide structural support. Subsequent grooves are then machined with reduced mechanical stress on the tool, as the preliminary grooves stabilize the disk structure. This preliminary action enables high precision machining while reducing tool wear.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3587017B1Method for the manufacture of a disc for a flow engine

Publication Date: 2021.02.17 MTU AERO ENGINES GMBH

Figure 1
Figure 2~3
Figure 4a~4b

AI summary

The present invention relates to a method for manufacturing a rotor disk (20) for a turbomachine (1) which forms blade root receptacles at several rotational positions (40.1, 40.2), wherein an axially extending profile groove (21) circumferentially bounded by inner wall surfaces of the rotor disk (20) is provided at each rotational position (40.1, 40.2), wherein a manufacturing process in a disk (20) is first introduced - first profile grooves (21.1) at first rotational positions (40.1) by machining material removal and - subsequently a second profile groove (21.2) is introduced circumferentially between the first profile grooves (21.1) at a second rotational position (40.2), wherein at least one second rotational position (40.2) is always arranged circumferentially between any two first rotational positions (40.1), and wherein, when introducing each second profile groove (21.2), a circumferentially adjacent first profile groove (21.1) is Profile groove (21.1) is supported on the interior wall surfaces (20a).