Bladed Stator Welding Tool for Flange Retraction Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The welding of vanes to the shell in turbomachine bladed elements causes internal stresses leading to deformations and retractions, which complicate post-weld machining and require replacement of non-conformant vanes, limiting further machining of already processed flanges.
Innovation Solution
A method involving a tool that exerts tensile forces on the flanges before and after welding to elastically deform the shell and flanges, compensating for retraction effects by repositioning them to their original shape, allowing for effective elimination of retraction phenomena without interfering with the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed to fix vanes to the shell, then the vanes are securely attached, but retraction and deformation occur due to internal stresses
Solution Approach 1:
A counteracting device is applied to the shell before welding to exert a force that opposes the retraction force that will occur during welding. This preliminary anti-action prevents the flange from deforming by counterbalancing the internal stresses that arise when the vanes are welded to the shell.
Solution Approach 2:
The counteracting device is installed and adjusted before the welding process begins, preparing the shell in advance to withstand the retraction forces. This preliminary setup ensures that when welding occurs, the flange remains stable and does not deform.
2Manufacturing precision
If post-weld machining is performed to correct deformations, then flange precision is restored, but additional machining operations are required increasing complexity
Solution Approach 1:
By applying the counteracting device before welding, the flange deformation is prevented at its source, eliminating the need for subsequent corrective machining operations. This approach simplifies the overall manufacturing process by avoiding the complexity of multiple machining steps.
3Reliability
If a non-conformant vane is replaced by machining the shell, then the defective vane is removed, but the flange cannot undergo further machining after welding
Solution Approach 1:
The counteracting device maintains the flange in its original position and prevents deformation during welding, ensuring that the flange remains machinable. This allows defective vanes to be removed and replaced with additional machining operations without compromising the flange's integrity or requiring complete redesign of the replacement process.
4Force
If the tool is made bulky to exert sufficient tensile force, then the compensating effect is enhanced, but the tool becomes difficult to handle and move between zones
Solution Approach 1:
The counteracting device is divided into multiple independent counteracting elements that can be individually applied to different circumferential zones of the shell. Each element can be independently adjusted and positioned, allowing the device to remain compact and mobile while still exerting sufficient tensile force on the flanges.
Solution Approach 2:
The counteracting device is designed to be dynamically adjustable, allowing it to be easily installed, adjusted, and removed from different positions on the shell. This dynamic design enables the tool to maintain adequate tensile force while remaining mobile and easy to operate across multiple circumferential zones.
5Ease of operation
If the tool is made compact for easy handling, then mobility is improved, but the tensile force exerted on flanges may be insufficient
Solution Approach 1:
Multiple compact counteracting elements work together to collectively exert sufficient tensile force on the flanges. Each individual element remains small and easy to handle, but their combined effect provides the necessary force to counteract welding retraction.
Solution Approach 2:
Several compact counteracting elements are combined in their action on the flanges, merging their individual forces to achieve the total tensile force needed. This combination allows the tool to remain mobile and easy to handle while still providing adequate force compensation.
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
This method effectively eliminates the retraction effects on the bladed element, enabling efficient manufacturing by maintaining the original shape and position of the flanges and shell, reducing the need for extensive post-weld machining and allowing for seamless integration of new vanes without further machining constraints.
Implementation Method 1
The purpose of the forces exerted on the flanges by the tool is to elastically deform at least one of the flanges and the shell in such a way that the movements thus obtained compensate for the retractions which will be exerted during the welding
Data Source
AI summary
Methods of manufacturing a bladed stator element for a turbomachine include mounting a tool on a circumferential zone of an annular shell prior to welding vanes in the circumferential zone, welding radially outer ends of the vanes to the annular shell, dismantling the tool after welding the vanes in the circumferential zone, and repeatedly mounting and dismounting the tool on different circumferential zones of the annular shell so as to fix the vanes all around the annular shell.