Adaptive machining and weld repair process
AssigneeHoneywell International Inc.
InventorsJames H. Graham, Jeffrey Reinwand, Roger G. Coriell, Kevin Lytle
Life of this patent
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Abstract
An apparatus and method are provided for an adaptive machining and weld repair process for repairing airfoils, damage to an airfoil leading edge and tip. First, damaged material is machined away from a damaged airfoil edge so as to expose a weld surface. New material is laser deposited on the weld surface so as to create a weld-repaired airfoil having actual dimensions. The actual dimensions of the weld-repaired airfoil are automatically measured using a CMM system so as to generate an actual geometry. The actual geometry is deformed so as to develop a deformation geometry. The component is then machined according to the deformation geometry.
Claims16
A method for restoring a worn edge of an airfoil comprising the steps of:
- machining away damaged material from a damaged airfoil edge so as to expose a weld surface;
- laser depositing new material on the weld surface so as to create a weld-repaired airfoil having actual dimensions;
- automatically measuring the actual dimensions of the weld-repaired airfoil using a CMM system so as to generate an actual geometry;
- deforming the actual geometry so as to develop a deformation geometry by:
- defining a set of streamlines on an airfoil surface,
- defining a set of cross curves that intersect one or more of the streamlines thereby establishing surface points at each such intersection,
- associating nominal surface data with each surface point,
- defining a set of inspection nominal points that fall on streamlines and cross curves,
- measuring an actual blade shape at each inspection nominal point to establish shape deviation data, and
- interpolating the shape deviation data with reference to the surface points;
- and
- machining the component according to the deformation geometry.
A method for restoring a worn edge of an airfoil comprising the steps of:
- machining away damaged material from a damaged airfoil edge so as to expose a welding area;
- laser depositing new material on the welding area so as to create a weld-repaired airfoil;
- defining a set of streamlines on an airfoil surface;
- defining a set of cross curves that intersect one or more of the streamlines thereby establishing surface points at each such intersection;
- associating nominal surface data with each surface point;
- defining a set of inspection nominal points that fall on streamlines and cross curves;
- automatically measuring the actual dimensions of the airfoil using a CMM system at each inspection nominal point to establish shape deviation data;
- interpolating the shape deviation data with reference to the surface points so as to create a deformation geometry;
- converting the deformation geometry to a machine operable code;
- machining the component according to the deformation geometry;
- and
- hand finishing the airfoil.
Dependencies are inferred from the claim text.