Viscous Media Flow Machining Tool for Aircraft Components

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Solution Overview

Problem

Aircraft components with complex geometries require high throughput and low-cost manufacturing, but existing abrasive flow machining techniques struggle to effectively process exterior surfaces without swelling or rounding edges, and often leave residue.

Innovation Solution

The development of viscous media flow machining tools that allow for the machining of both interior and exterior surfaces by configuring a tool body with a cavity and work piece holder, using a seal door to control media flow, and employing a media flow path that directs viscous or chemically erosive media to form and machine surfaces without swelling or unintended rounding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If abrasive flow machining is used to smooth interior channels, then surface finish is improved, but edges are rounded and residue builds up in bends

Engineering Contradiction:

Improvesurface finishVSAvoidedge sharpness

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent inverts the traditional abrasive flow machining approach by placing the abrasive media source outside the component and using a pump-driven circulation system. The media flows through controlled pathways that direct abrasive action away from edges and bends, preventing rounding and residue buildup while maintaining interior surface smoothing capabilities

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention employs a hydraulic/pneumatic pump system to circulate abrasive media through controlled flow paths. This allows precise regulation of media flow rate and direction, enabling selective abrasive action on interior surfaces without the uncontrolled pressure that causes edge rounding and bend residue in conventional methods

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If high pressure is applied during abrasive flow machining, then machining speed is improved, but the component swells

Engineering Contradiction:

Improvemachining speedVSAvoiddimensional stability

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The patent uses a controlled hydraulic/pneumatic circulation system with a pump to deliver abrasive media at regulated pressures. This replaces uncontrolled high-pressure application with precisely managed pressure cycles, enabling high machining speeds through efficient media circulation while preventing component swelling via controlled pressure application and release cycles

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The invention implements continuous circulation of abrasive media through a closed-loop pump system. This maintains consistent, controlled pressure application over time rather than intermittent high-pressure bursts, achieving high productivity through sustained efficient machining while preventing dimensional instability through continuous pressure regulation

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If conventional abrasive flow machining is used, then interior surfaces can be machined, but exterior surfaces cannot be accessed

Engineering Contradiction:

Improvesurface accessibilityVSAvoidtooling configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal abrasive flow machining system where a single pump-driven circulation apparatus can machine both interior and exterior surfaces. The flexible media delivery system with multiple pathways and spray nozzles allows the same equipment to adapt to different surface types, eliminating the need for separate tooling configurations for interior versus exterior machining

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables the precise machining of exterior surfaces while preventing residue buildup and edge rounding, allowing for the formation of complex geometries with improved efficiency and cost-effectiveness in aircraft component manufacturing.

Implementation Method 1

Abrasive flow machining can be used to surface smooth interior channels

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11577355B2Closed chamber abrasive flow machine systems and methods

Publication Date: 2023.02.14 THE BOEING CO

AI summary

Systems and methods are provided for viscous and/or chemically erosive flow machining of work pieces. In certain examples, a tool for flow machining may be disclosed. The tool may include a cavity configured to receive a work piece and one or more inlets and outlets for viscous media flow. Viscous media and/or chemically erosive media can be flowed into the cavity and, via a media flow path, can be used to machine the work piece.