Superabrasive Tool Central Recess for Turbomachine Grinding
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Solution Overview
Problem
Existing machining technologies face challenges in efficiently machining turbomachine components, particularly in achieving effective grinding at the center of the quill tip and addressing the lack of grinding action, which limits precision and efficiency in manufacturing components like integrally bladed disks and turbine engine cases.
Innovation Solution
A superabrasive machining tool with a central recess and elongate recesses on its tip end, coated with abrasive materials like cubic boron nitride or diamond, is designed for high-speed rotation and reorientation to enhance grinding effectiveness, allowing for precise machining of complex surfaces and features in turbomachine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional quill tip is used for superabrasive machining, then the tool structure is simple, but there is a lack of grinding action at the center of the quill tip
Solution Approach 1:
The quill tip is segmented into multiple functional zones: a central recess area that receives coolant and a peripheral abrasive coating area that performs grinding. This segmentation allows the central region to serve a different function (coolant delivery) while the peripheral region maintains the grinding function, thereby resolving the contradiction between simplicity and grinding effectiveness.
Solution Approach 2:
The quill tip is given different local qualities: the central region has a recess with different functional properties (coolant reception) compared to the peripheral region which has abrasive coating. This local differentiation enables effective grinding at the periphery while the center handles coolant management, improving overall machining precision without requiring complete structural complexity.
2Productivity
If the quill rotates at high speed, then productivity increases, but control and stability become more difficult
Solution Approach 1:
A coolant intermediary is introduced through the central recess to manage the high-speed rotation effects. The coolant flows through the recess and onto the workpiece, providing thermal management and lubrication that stabilizes the machining process at high speeds, thereby maintaining reliability while achieving high productivity.
Solution Approach 2:
The system changes physical parameters by introducing coolant flow through the central recess at high rotation speeds. This parameter change (coolant introduction) allows the system to maintain stability and control during high-speed operation, resolving the contradiction between productivity and reliability.
3Ease of manufacture
If abrasive material is applied as a coating, then the tool can be easily manufactured, but the coating may wear and require frequent replacement
Solution Approach 1:
The central recess provides continuous coolant flow that cools and lubricates the abrasive coating during machining. This continuous action extends the coating service life by preventing overheating and reducing wear, thereby maintaining the useful action of the coating for longer periods while keeping the manufacturing process simple.
Solution Approach 2:
The coolant flow through the central recess provides beforehand cushioning by continuously cooling and lubricating the abrasive coating before excessive wear occurs. This protective action extends the coating life and reduces the frequency of replacement, resolving the contradiction between ease of manufacture and service life.
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
The tool enables efficient machining of turbomachine components with improved precision and reduced material removal challenges, allowing for the formation of interblade floors and exterior pockets in nickel- or cobalt-based superalloys and titanium alloys with high-speed rotation and reorientation capabilities.
Implementation Method 1
A body extends along a central longitudinal axis from a first end to a tip end. An abrasive material is located on the tip end... by rotating the tool about the central longitudinal axis... removing material at the contact
Data Source
AI summary
A tool for use in an abrasive machining process has a body extending along a central longitudinal axis from a first end to a tip end. An abrasive material is located on the tip end. A central recess is formed in the tip end.