Turbine Blade Blank Machining Single Clamping
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Solution Overview
Problem
The current manufacturing process for turbine blades requires multiple processing steps and complex clamping devices due to their complex 3D shape, leading to increased time, cost, and difficulty in maintaining narrow tolerance ranges, especially for large and heavy workpieces.
Innovation Solution
A method using a rotary milling machine with a clamping device and counter center to hold the blank in a single clamping position, allowing for all-round machining, including turning, milling, and drilling, to produce turbine blades in as few steps as possible, eliminating the need for multiple clamping operations and reducing clamping errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processing steps are used on different machines, then the complex 3D shape of turbine blades can be manufactured, but the production time increases and tolerance maintenance becomes difficult
Solution Approach 1:
The patent combines multiple processing steps (turning, milling, drilling) that were previously performed on separate machines into a single integrated processing machine. The workpiece is clamped once and all operations are performed in one setup, eliminating repeated clamping and repositioning. This merging of operations maintains tight tolerances while significantly reducing production time.
Solution Approach 2:
The processing machine is designed with multi-functionality to perform turning, milling, drilling, and other operations on a single machine platform. This universal machine can handle all required manufacturing operations for turbine blades without requiring transfer to different specialized machines, thereby maintaining precision and reducing time loss.
2Manufacturing precision
If complex clamping devices are used to maintain tolerance ranges, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a simple clamping device that clamps the workpiece once at the beginning. All subsequent processing operations are performed while the workpiece remains clamped in the same position. This eliminates the need for complex re-clamping devices and multiple holders, reducing device complexity while maintaining tolerance through consistent positioning.
Solution Approach 2:
The workpiece is clamped in advance at the beginning of the process and remains clamped throughout all processing steps. This preliminary clamping action ensures the workpiece maintains its position and orientation for all operations, eliminating the need for complex intermediate clamping devices.
3Manufacturing precision
If tandem axes are used for clamping and movement, then the workpiece can be positioned, but acceleration speed decreases due to tracking errors
Solution Approach 1:
The patent extracts the clamping function from the moving tandem axis system and places it on a stationary structure. The clamping device remains fixed while only the processing tools move, eliminating tracking errors between clamping and movement axes. This allows the moving axes to accelerate without the constraints of maintaining clamping position.
Data Source
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AI summary
In order to carry out complete machining of a blank (RL) on a machine tool, such as, for example, a rotary miller (HSTM), the blank (RL) is held in at least one clamp (SM) during a machining step. All the functional surfaces of the workpiece (circumference and both end faces of the blank) are brought into the final required form corresponding to final use by the machine tool, in particular, the rotary miller. The blank (RL) is a blank made from metal or a ceramic material, of cylindrical, square, or polyhedral cross-section, in particular, a rectangular block or any shaped cast or forged blank. The required form is the head of a turbine blade, the blade region of the turbine blade and the root of the turbine blade, wherein the functional surfaces of the head and root are prepared during a clamped phase on the machine tool (HSTM).