Generator rotor refurbishing system and method of repairing a generator rotor

A generator rotor refurbishing system comprising:

• a cutting tool configured to cut generator rotor bars, the cutting tool including:
• a clamping apparatus comprising a first clamping surface and a second clamping surface;
• a guide track configured and disposed to be fixedly mounted relative to a generator rotor;
• a cutting head block moveable along the guide track perpendicular to the first clamping surface and the second clamping surface and including a blade element movable in a direction substantially perpendicular to the movement of the cutting block head within the guide track to achieve a first fixed depth, substantially square cut;
• and
• an adjustment block adapted for installation between the cutting block head and the guide track,
• whereby the cutting tool is configured and disposed for a second cutting operation to produce a second cut through another generator bar arranged below the generator rotor bar without moving the guide track, the second cut being laterally and axially off-set from the first cut.

A cutting tool comprising:

• a guide track including a guide slot;
• a cutting head block moveably mounted relative to the guide track, the cutting head block including a straight-edged blade element movable in a direction substantially perpendicular to the movement of the cutting block head within the guide track, the straight-edged blade element being configured and disposed to produce a first fixed depth cut;
• a guide block disposed between the cutting head block and the guide track, the guide block including a slot member extending into the guide slot;
• a pair of rib elements disposed between the slot member and a surface of the guide slot;
• and
• an adjustment block adapted for installation between the cutting block head and the guide track,
• whereby the cutting tool is configured and disposed for a second cutting operation to produce a second cut through another generator bar arranged below the generator rotor bar without moving the guide track, the second cut being laterally and axially off-set from the first cut.