Metrology enabled airfoil manufacturing. Ben Taylor Renishaw plc

Transcription

1 Metrology enabled airfoil manufacturing Ben Taylor Renishaw plc

2 Metrology-enabled airfoil manufacturing Challenges in modern airfoil manufacturing Metrology the data thread that connects and enables automated operations Adaptive machining Shop-floor gauging Rapid, comprehensive verification Process characterisation

3 Challenges in modern airfoil manufacturing Fuel efficiency pressure 20% reduction by 2020 Precise leading / trailing edge profiles Reduced component count resulting in complex geometries Manufacturing cost and quality concerns driving process automation Data-led design and engineering Reproduced with the permission of Rolls-Royce plc, copyright Rolls-Royce plc 2009

4 Implications for measurement Accurate, comprehensive understanding of airfoil form Before, during and after each manufacturing stage Rapid, automated data acquisition Step change in speed, accuracy and capability Shorter process development times Data information action

5 Metrology-enabled airfoil manufacturing Data connecting and enabling automated operations Adaptive machining Shop floor gauging Verify & characterize

6 Adaptive machining Adapt machining to fit the actual input condition of the part Blend machined and formed surfaces Applications Friction-welded blisks Blade tip refurbishment Snubber fins

7 Adaptive machining Measurement needs High volume, high density data On-machine measurement Integrated process Short cycle time

8 New technology on-machine scanning 1000 points / sec Short cycle time Accurate blends Part quality assured

9 Adaptive machining for blisk root blending

10 New technology versatile gauging Comparative gauge Scanning solution captures form Robust for the shop-floor Re-master to adapt to temperature change Many parts / operations Rapid re-programming for design changes Cost-effective

11 Versatile airfoil gauging Form measurement by scanning Scanning probe measures size, location and form System capable of high speed scanning

12 Nozzle guide vane conventional dedicated gauging Dedicated to a single part and operation Single gauge point measurement Multiple nests per part Expensive to reconfigure for design changes or new parts

13 Nozzle guide vane Equator versatile gauging Ambient temperature compensated by remastering Full 3D measurement Measures a range of parts Simple operator interface Single phase power requirement with no compressed air supply

14 Complex airfoil measurement tasks Require Comprehensive verification Complex feature geometries Edge profiles and surface blends Surface finish Previously lead to Long inspection cycle times Inspection bottlenecks

15 Look between the lines! Blades are normally inspected in sections due to the limitations of historic measurement techniques But what if you could accurately and quickly measure the whole blade?

16 Look between the lines! Now, unlimited sections or full surface analysis is possible.

17 New technology Blade Inspection Toolkit Automated, high speed point cloud capture for comprehensive blade verification and characterisation APEX Blade Modus Modus Reporter 1. Automatic 5-axis sweep scan program generation 2. High speed point cloud data collection 3. Section point cloud, evaluate & report

18 1. Automatic Collision Free Path planning APEX Blade Set scan parameters Plan sweeps Simulate Generate CMM program (DMIS)

19 2. High speed point cloud data collection

20 3a. Define sections from CAD model

21 3b. Determine sections from point cloud

22 3c. Reporting ~ Airfoil and Profile Characteristics

23 Data for Engineering Surfit Blade Reverse engineered NURBS surface Aerodynamic analysis Stress Analysis Average blade geometry can be established from a number of blades

24 Metrology-enabled airfoil manufacturing summary Automated adaptive machining Shop floor process control Comprehensive verification & characterisation Engineering data

25 Thank you apply innovation