Turbine Disk Slot Machining with Interchangeable Tools
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Solution Overview
Problem
The existing broaching technique for manufacturing turbine disks is expensive and time-consuming due to the need for specially manufactured rails for each unique slot design, limiting efficiency and increasing costs.
Innovation Solution
A machining technique using a milling machine with interchangeable cutting tools to create slots in three forms: initial, intermediate, and final, allowing for the creation of complex slot designs using standard and specially shaped tools, reducing the need for custom rail manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If broaching technique with specially manufactured rails is used for each unique slot design, then manufacturing precision of slot shape is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent applies universality by using a single broaching machine that can machine multiple different slot designs through programmable control. Instead of requiring specially manufactured rails for each unique slot design, the system uses a universal broaching machine with computer-controlled motion that can adapt to various slot geometries through software programming, thereby reducing device complexity while maintaining manufacturing precision
Solution Approach 2:
The patent applies parameter changes by modifying the control parameters and motion paths of the broaching machine rather than changing the physical rails. By programmatically adjusting cutting paths, speeds, feeds, and tool positions, the system can produce different slot designs using the same hardware, eliminating the need for custom rail manufacturing for each design variation
2Manufacturing precision
If specially manufactured rails are created for each slot design, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent applies preliminary action by pre-programming the broaching machine with various slot design patterns and cutting paths before actual production. The system prepares digital models and machining parameters in advance, allowing rapid switching between different slot designs without the time-consuming process of manufacturing custom rails for each design
Solution Approach 2:
The patent applies copying by using digital models and virtual representations of slot designs to control the broaching process. Instead of creating physical rails for each design, the system copies the desired slot geometry into digital form and uses computer-controlled motion to replicate these designs on the workpiece, dramatically reducing preparation time
3Manufacturing precision
If multiple specialized cutting tools are used for different slot forms, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by using a single multi-functional cutting tool that can machine different slot forms through programmable control. The broaching machine is equipped with a universal tool that can be controlled via computer to create various slot geometries by adjusting motion paths and cutting parameters, eliminating the need for multiple specialized tools while maintaining precision
Solution Approach 2:
The patent applies dynamics by making the cutting tool's motion and orientation dynamically adjustable through computer control. Instead of requiring static specialized tools for each slot form, the system uses a single tool with dynamically programmable paths that can adapt to different slot geometries in real-time, reducing tool inventory while maintaining manufacturing precision
Data Source
AI summary
A method of manufacturing a turbine disk involves machining to an initial form a slot in a turbine disk using a firm cutting tool. An intermediate form is then machined using a second cutting tool different from the first cutting tool. A final form using a third cutting tool different from the first cutting tool and the second cutting tool is then machined.