Turbomachine Component Machining Using Distance-Based Toolpaths
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Solution Overview
Problem
Turbomachine components, especially those with complex geometries and varying states due to previous processing or use, require an efficient method for material removal that accounts for individual differences and deformations, as existing methods lack precision and efficiency in targeted processing.
Innovation Solution
A method involving non-contact distance imaging, comparison with a computer model, and automated tool path creation for spark erosion, laser drilling, or conventional drilling, allowing for precise and efficient material removal by aligning the machining tool along a determined path, which can adapt to component deviations and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated tool path creation based on distance imaging and computer model comparison is implemented, then manufacturing precision and adaptability to component variations are improved, but device complexity and initial processing time increase
Solution Approach 1:
The system performs preliminary actions by capturing distance images and comparing them with computer models before actual machining begins. This allows the tool paths to be pre-calculated and optimized based on the actual component geometry, ensuring high machining precision while automating the adaptation to component variations.
Solution Approach 2:
The invention uses computer models as digital copies of the component geometry and distance images as optical copies of the actual surface. By comparing these copies with the target geometry, the system automatically generates accurate tool paths without requiring manual measurement and programming, thereby improving precision while managing system complexity through software-based solutions.
2Adaptability or versatility
If automated tool path creation based on distance imaging is used, then adaptability to component deviations is improved, but loss of time in measurement and data processing increases
Solution Approach 1:
The invention replaces manual measurement and tool path programming with automated optical measurement and computer-based processing. Distance imaging systems capture component geometry non-contactly, and software algorithms automatically compare the measured data with computer models to generate tool paths, eliminating manual operations and reducing overall processing time despite the additional measurement step.
Solution Approach 2:
The system implements feedback by continuously comparing distance images with computer models and automatically adjusting tool paths based on the detected deviations. This closed-loop approach enables the system to adapt to component variations efficiently, as the measurement and correction processes are integrated and automated, reducing the time penalty associated with adaptability.
3Productivity
If spark erosion with automated tool path generation is used, then productivity is improved for components with many locations, but device complexity increases due to integration of measurement and machining systems
Solution Approach 1:
The invention merges the measurement system (distance imaging) with the machining system (spark erosion apparatus) into an integrated automated system. The computer control unit coordinates both functions, allowing seamless transition from measurement to tool path generation to machining. This integration eliminates manual intervention between steps and enables continuous automated operation, significantly improving productivity for components with numerous machining locations.
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 approach enables automated, highly precise material removal processes, reducing processing time and improving consistency across components with diverse histories, particularly beneficial for turbomachine components like combustion chamber linings with numerous holes and varying conditions.
Implementation Method 1
The distance image is preferably recorded on the basis of a time of flight
Implementation Method 2
material removal is based on electrical discharge processes between the tool, i.e., the electrode, and the electrically conductive component
Implementation Method 3
laser drilling or conventional drilling is used
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
The present invention relates to methods for material removal machining of a component (23) for a turbomachine (1), comprising the steps: i) recording (61) a distance image (20) by non-contact measurement of at least one surface (21) of the component (23) to be machined; ii) comparing the distance image (20) with a computer model (30) of the component (23) and determining the areas (46) of the component (23) to be machined based on deviations between the distance image (20) and the computer model (30); iii) creating a toolpath (66) for the areas (46) of the component (23) to be machined; iv) material removal machining (64) of the component (23) based on the toolpath (66) by electrical discharge machining, laser drilling or conventional drilling.