Adaptive machining and weld repair process

• US 20070251072A1
• Filed: 04/28/2006
• Published: 11/01/2007
• Est. Priority Date: 04/28/2006
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Beeson, William, Weaver, Greg, Cahoon, Christopher
• Granted Patent: US 7,797,828 B2
• Time in Patent Office: Days
• US Class Current: 29/402.10
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/10 by removing material
• CPC Class Codes: F05D 2230/30 with deposition of material
• CPC Class Codes: G05B 2219/32228 Repair, rework of manufactured article
• CPC Class Codes: Y10T 29/49229 Prime mover or fluid pump making
• CPC Class Codes: Y10T 29/49236 Fluid pump or compressor making
• CPC Class Codes: Y10T 29/49238 Repairing, converting, servicing or salvaging
• CPC Class Codes: Y10T 29/49718 Repairing
• CPC Class Codes: Y10T 29/49732 by attaching repair preform, e.g., remaking, restoring, or patching
• CPC Class Codes: Y10T 29/49734 and removing damaged material
• CPC Class Codes: Y10T 29/49746 by applying fluent material, e.g., coating, casting

Abstract

The present invention provides an apparatus and method for an adaptive machining and weld repair process useful for repairing airfoils, particularly damage to an airfoil leading edge and tip. The process first machines away damaged portions of the airfoil. Next, the actual profile of the airfoil subsequent to the removal of the damaged material is measured using a Coordinate Measuring Machine. The data is then used to generate a deformation profile. Filler material is then added to the machined area using the data of the deformation profile to produce an airfoil that approximates the ideal shape of a restored airfoil. At this point, the actual profile of the welded airfoil is measured using the Coordinate Measuring Machine. The data is then used to generate a deformation profile and the airfoil is machined using the date of the deformation profile to produce that shape. The adaptive technology minimizes the amount of stock on material that needs to be removed by hand. The technique thereby significantly reduces costly manual processing.

Claims

1. A method for restoring a worn engine component comprising the steps of:

removing damaged material from a worn surface of the component thereby exposing a weld surface;

measuring the component at the weld surface to generate a first plurality of component measurements;

developing a first deformation component geometry based on the first plurality of component measurements;

depositing a filler material on the weld surface;

measuring the component at a surface of the filler material to generate a second plurality of component measurements;

developing a second deformation component geometry based on the second plurality of component measurements; and

machining the component to the second deformation component geometry.

2. The method according to claim 1 wherein the steps of measuring the component further comprises measuring using a coordinate measuring machine (CMM).

3. The method according to claim 1 further comprising the steps of generating a first tool path in response to the first deformation component geometry and generating a second tool path in response to the second deformation component geometry.

4. The method according to claim 3 wherein the step of generating a first tool path comprises generating a tool path for automated welding of the filler material to the weld surface.

5. The method according to claim 3 wherein the step of generating a second tool path comprises generating a tool path for automated machining of the filler material.

6. The method according to claim 1 wherein the step of depositing a filler material comprises laser cladding.

7. The method according to claim 1 wherein the step of machining the component includes machining the component so as to leave less than 5 thousandths of an inch stock on.

8. The method according to claim 1 further comprising the step of hand finishing the machined component.

9. 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;

measuring the damaged airfoil edge at the weld surface using a CMM system to generate a plurality of component measurements;

developing a first deformation component geometry based on the plurality of component measurements;

depositing a filler material on the weld surface according to the first deformation component geometry so as to create a weld-repaired airfoil having actual dimensions;

measuring the actual dimensions of the weld-repaired airfoil using a CMM system so as to generate an actual geometry;

developing a second deformation component geometry based on the actual geometry; and

machining the component according to the second deformation component geometry.

10. The method according to claim 9 further comprising the step of converting the first deformation geometry to automated welding data.

11. The method according to claim 10 wherein the step of depositing a filler material on the weld surface further comprises automated welding according to the automated welding data.

12. The method according to claim 9 further comprising the step of converting the second deformation geometry to CNC machining data.

13. The method according to claim 12 wherein the step of machining the component further comprises automated machining according to the CNC machining data.

14. The method according to claim 9 wherein the step of machining away damaged material from a damaged airfoil edge comprises machining away a damaged leading edge.

15. The method according to claim 9 wherein the step of machining away damaged material from a damaged airfoil edge comprises machining away a damaged trailing edge.

16. The method according to claim 9 wherein the step of machining away damaged material from a damaged airfoil edge comprises machining away a damaged top edge.

17. The method according to claim 9 wherein the steps of developing a first deformation component geometry and a second deformation component geometry further comprises:

defining a set of streamlines on the 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.

18. 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;

defining a set of streamlines on the 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 the damaged airfoil edge at the weld surface using a CMM system to generate a plurality of component measurements;

interpolating the shape deviation data with reference to the surface points so as to create a first deformation geometry based on the plurality of component measurements;

converting the first deformation geometry to a welding system operable code;

depositing a filler material on the weld surface according to the first deformation geometry so as to create a weld-repaired airfoil;

automatically measuring the 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 second deformation geometry;

converting the second deformation geometry to a machine operable code;

machining the component according to the second deformation geometry; and

hand finishing the airfoil.

19. The method according to claim 18 wherein the step of machining the component further comprises machining the component so as to leave less than 0.005 inch of material stock on.

20. The method according to claim 18 further comprising the step of transferring the first deformation geometry to an automated welding computer to generate a tool path using software, and transferring the second deformation geometry to an automated machining computer to generate a tool path using machining software.