Textured Deep Rolling Tool for Controlled Stress on Fan Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing deep rolling tools are expensive, complex, and inefficient, with hydraulic systems requiring constant maintenance and adjustment, and they struggle to apply consistent contact stress for optimal material properties, leading to potential damage and defects in fan blades.
Innovation Solution
A system featuring a roller tool with a textured roller and dynamic force controller, supported by a robotic arm, which applies controlled compressive stresses and imprints surface textures on fan blades, ensuring consistent contact stress and avoiding collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydraulic burnishing tools are used for complex geometries, then surface treatment precision is improved, but device complexity and cost increase due to hydraulic systems requiring constant maintenance and adjustment
Solution Approach 1:
The patent removes the hydraulic system from the deep rolling tool, extracting the complex pressure control mechanism and replacing it with a simpler mechanical or electric actuation system. This eliminates the need for hydraulic pumps, valves, and constant maintenance while achieving the required contact stress control through direct mechanical means.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an alternative actuation mechanism that can provide controlled contact stress without requiring fluid pressure systems. This substitution eliminates the complexity of hydraulic maintenance and adjustment while maintaining the ability to apply precise controlled loads to the workpiece surface.
2Measurement precision
If ball bearing contact area is reduced for precision, then measurement precision is improved, but productivity decreases due to slower production time and throughput
Solution Approach 1:
The patent divides the contact surface into multiple discrete contact points or zones along the rolling path, allowing the tool to process multiple areas of the workpiece surface in sequence. This segmentation enables precise control at each contact point while increasing overall productivity by covering a larger total surface area through multiple passes or positions.
Solution Approach 2:
The patent transitions from a single-point contact approach to a distributed contact system that operates along the length of the rolling tool or workpiece. By utilizing the longitudinal dimension of the contact interface, the system maintains precision at each point while processing a larger total area, thereby increasing throughput without sacrificing precision.
3Strength
If contact stress is increased to improve material properties, then strength is improved, but reliability decreases due to potential material damage and defects
Solution Approach 1:
The patent implements a dynamic contact stress control system that adjusts the applied load in real-time based on workpiece geometry, material properties, and processing location. This dynamic adjustment ensures optimal contact stress is applied to achieve desired material strengthening while preventing excessive stress that could cause surface damage or subsurface defects, thereby maintaining both strength and reliability.
Solution Approach 2:
The patent incorporates a feedback mechanism that monitors the contact stress applied during deep rolling and adjusts the loading accordingly. This feedback control ensures that the contact stress remains within the optimal range for generating compressive residual stresses without exceeding the material's elastic limit, thus preventing permanent damage while achieving the desired strengthening effect.
4Manufacturing precision
If hydraulic pressure is constantly adjusted for precision, then manufacturing precision is improved, but loss of time increases due to maintenance and adjustment requirements
Solution Approach 1:
The patent designs the contact stress control system to be self-regulating or self-adjusting, eliminating the need for constant manual intervention or maintenance. The system automatically maintains the required contact stress through inherent mechanical properties, pre-set parameters, or automated control, thereby reducing downtime for adjustments and maintenance while preserving manufacturing precision.
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 system enhances fatigue life and coating bonding by inducing residual compressive stresses while maintaining a smooth surface finish, improving production efficiency and reducing defects.
Implementation Method 1
Deep Rolling (DR) is a type of surface treatment. The Deep Rolling process uses a roller to roll the surface under controlled load & speed. The rolling pressure induces a deep layer of compressive residual stress.
Implementation Method 2
This can improve coating bonding or tribological properties as well as increase fatigue life or maintain fatigue life in the presence of damage.
Data Source
AI summary
A system for deep rolling a workpiece including a roller tool comprising an adaptor plate proximate an adapter end; an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end; and a roller disk joined to the roller end, the roller disk including a surface feature configured to contact the workpiece and imprint a surface texture on a workpiece surface.