Robotic deep rolling tool design for mechanical surface treatment of extremely complex and tight clearance blade root geometry

A system for deep rolling a fan blade comprising:

• a roller tool comprising a dynamic force controller in operative communication with an adaptor plate proximate an adapter end;
• an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with a root of the fan blade;
• a roller disk support attached to the roller end, the roller disk support comprising a pair of forks;
• a roller disk joined to the pair of forks, the roller disk configured to contact the root;
• and
• a fixture supporting the fan blade;
• the fixture comprising:
• a body including an upper region opposite a lower region, the body includes a front and a rear opposite the front, the body includes a right side and a left side opposite the right side;
• the body supports a pivot clamp, the pivot clamp attaches to the body with a pivot attached to the body;
• a support attached to the body, the support includes at least one brace coupled to the rear of the body, the support is configured to engage an airfoil portion of the fan blade;
• a receiver formed in the body configured to support the root of the fan blade, wherein the receiver includes at least one landing configured to support a corresponding portion of the root;
• and
• a shoulder attached to the body configured to support a platform portion of the fan blade;
• wherein the shoulder is located in an upper region of the body between the receiver and the support.

A process for forming a roller tool for deep rolling a fan blade comprising:

• the roller tool comprising an adaptor plate proximate an adapter end;
• attaching an arm to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the fan blade;
• attaching a roller disk support to the roller end, the roller disk support comprising a pair of forks;
• joining a roller disk to the pair of forks, the roller disk configured to contact the fan blade;
• and
• supporting the fan blade with a fixture.