Shroud Block Machining Radial Support Alignment
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Solution Overview
Problem
Current methods for machining bore holes in shroud blocks for turbine systems are inaccurate and time-consuming, leading to inefficiencies and increased downtime in turbine system operations due to the need for repeated machining and potential leakage issues.
Innovation Solution
A machining kit and method that includes a designation device, machining device, and radial support to accurately align and position shroud blocks, ensuring precise machining of bore holes along the radial axis, using a locating tool and machining tool within a platform and securing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shroud block is placed on a flat planar surface for machining, then the machining process is simplified, but the bore holes are machined at inaccurate angles
Solution Approach 1:
A radial support is introduced as an intermediary element between the shroud block and the planar surface. The radial support has a radial exterior surface that mates with the radial outer surface of the shroud block, providing a reference that ensures accurate radial alignment and correct bore hole angles while maintaining the simplicity of planar surface machining.
2Productivity
If bore hole locations are approximated based on mating bore holes, then the machining process is faster, but the bore holes cannot be mounted properly and allow leakage
Solution Approach 1:
The radial support is prepared in advance with the correct radial orientation and positioning features. By pre-configuring the radial support with the accurate radial reference, the shroud block can be quickly positioned and machined without time-consuming measurements or approximations, achieving both speed and precision.
3Manufacturing precision
If repeated machining is performed to modify bore holes, then the bore holes can be made to perform adequately, but the time during which the turbine system is shut down increases
Solution Approach 1:
The complex iterative mechanical adjustment process of repeated machining is replaced by a single-pass accurate machining process using the radial support fixture. The radial support provides built-in alignment and positioning features that eliminate the need for multiple trial-and-error machining operations, significantly reducing downtime.
Data Source
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AI summary
A method and a machining kit (40) for machining a bore hole (24) into a shroud block (22) are disclosed. The method includes designating a location (42) of the bore hole (24) on an exterior surface (44) of the shroud block (22), positioning the shroud block (22) in a machining device (60), securing the shroud block (22) in the machining device (60), and machining the bore hole (24) in the shroud block (22). The machining device (60) includes a locating tool (82), a machining tool (84), a platform (62), a securing device (64), and a radial support (66). The radial support (66) is configured to mate with a radial exterior surface (48) of the shroud block (22) such that a machining axis (72) of the machining device (60) may be aligned with a radial axis (70) of the shroud block (22) during positioning.