Miniaturized turbogenerator for the direct electrical propulsion of automotive, urban air mobility, and small marine vehicles

A method of manufacturing a miniaturized turbogenerator where bladed disk components of a gas turbine engine are manufactured from a workpiece by a process comprising the steps of:

• a) providing an asymmetrical cutting tool having an angled or curved shaft to clear any machined features of the workpiece that is attached to a non-spindle multi-axis computer numerical control (CNC) machine tool;
• b) adjusting a position of the cutting tool at a sufficient distance from the workpiece so that an acceleration of the cutting tool is sufficient to induce controlled fracturing upon impact with the workpiece;
• c) accelerating the cutting tool to a point of impact with the workpiece;
• d) driving the cutting tool with a sufficient linear force of at least 20,000 lbs/in2 to induce and maintain controlled fracturing for material removal;
• e) moving at a rate of motion of 1200 inches/minute through the workpiece such that the rate of motion is at least one magnitude greater in feed rate than a rotating axially symmetric fluted cutting tool and wherein the workpiece material is micro-cracked allowing the cutting tool to shear material from the workpiece as waste, retaining a majority of the heat generated in the waste in that an end result of the controlled-fracturing is a shape cut into the workpiece with a same contour as the cutting tool such that an overall size of the workpiece is greatly reduced in scale for producing a turbine having at least twenty-eight (28) blades such that a thickness of the blades is thinner in cross-section than those provided by rotary machining;
• f) following a three-dimensional tool path that removes material from the workpiece to produce a plurality of blades and volutes that conform to a perimeter of a cutting face of the cutting tool to produce a plurality of compound-curved shapes so each one of the blades are folded over a neighboring blade;
• g) adjusting the cutting face of the cutting tool such that a finished surface to be produced is oriented perpendicularly to a cutting edge of the cutting tool and the cutting face is always normal to the tool path;
• and
• h) upon reaching an end of the tool path, steps a) to g) are repeated until a precise net shape of compressor and turbine blades and the volutes between the blades is produced.