T. Dziubek

Rapid prototyping in manufacturing of core models of aircraft engine blades

Purpose – The purpose of this paper is to present the advantages of computer-aided design/rapid prototyping (CAD/RP) usage in designing and manufacturing of the core models used for precise casting with direct and single solidification of aircraft engine turbine blade cores. Design/methodology/approach – The process of modelling three-dimensional CAD geometry of research blade in relation to the model of the core was presented with different wax types used in the RP technique. Findings – The geometry of the blade model has been designed in a way which allows making a silicon mould on the basis of a base prototype in the process of rapid tooling (RP/RT). Filing by different wax types was investigated in mean of the impact on filling accuracy of the mould cavity. Originality/value – The resulting models were used to make ceramic moulds and carry further work on the development of casting technology in the process of directional solidification and single crystal solidification of core blades of aircraft engines.

Manufacturing of aircraft engine transmission gear with SLS (DMLS) method

Purpose The purpose of this paper is to present the methodology for manufacturing of aircraft transmission gears using incremental method of rapid prototyping (RP) – direct metal laser sintering (DMLS). The production of prototypes from metallic powders using described system allows the execution of final elements of complex structures with additional economic impacts. Design/methodology/approach The paper describes the use of selective laser sintering method (DMLS) by EOS Company. Whole chain of production of prototype is presented with the addition of geometric accuracy measurements by blue light laser device. Findings Presented in the research analysis of SLS/SLM technologies as rapid manufacturing systems shows that they can be applied in the production of prototypes used in the manufacturing process of gears for propulsion systems in aviation industry. Also, very important is the geometrical accuracy of gear prototypes produced by incremental methods. It determines subsequent treatment steps for aircraft propulsion system gears. Practical Implications The use of RP techniques as an alternative for conventionally used manufacturing method has mainly an economic impact related to the cost of time-consuming process and amount of defected elements appearing in serial production. Originality/value This paper presents possibility to use RP – DMLS system – for propulsion elements of aircraft structure. This research is original because of the complex description of the whole chain of manufacturing process. Additionally, geometrical accuracy measurement methodology by blue light presented with the RP method of manufacturing gives the research a unique characteristic.

The assessment of geometric accuracy of aircraft engine blades with the use of an optical coordinate scanner

Purpose The purpose of this paper is to present coordinate measuring system possibilities in the meaning of the geometric accuracy assessment of hot zone elements in aircraft engines. The aim of the paper is to prove that this method, which uses blue light and is most sufficient and cost-saving method, can to be used in the production line for serial manufacturing of elements, for which a high level of accuracy is required. Design/methodology/approach The analysis of the geometric accuracy of the blades was performed using non-contact optical coordinate scanner ATOS Triple Scan II Blue Light, manufactured by GOM Company, at the Department of Mechanical Engineering, Rzeszow University of Technology. Geometric analysis was conducted for blades manufactured from different waxes (A7Fr/60 and RealWax VisiJet CPX200), thus comparing injection technique and rapid prototyping (RP) method, and for casting made of Inconel 713C nickel-based superalloy. Findings The analysis of the criteria for the method of blades’ measuring selection showed that the chosen system successfully met all criteria for the verification of blades’ geometry at the selected stages of the process. ATOS II optical scanner with blue light technology allows measurement almost regardless of daylight or artificial (white) light. This allows the application of the measurement system in the production cycle, thus eliminating the need to create special conditions for measurements. Practical implications Requirements related to the accuracy of measured values, diversity and allowable measurement time are linked with the methods of production. Modern manufacturing methods based on computer-aided design systems/manufacturing/engineering systems require a non-contact optical measurement method based on the computer-aided-based coordinate measuring technique. In case of the non-contact optical scanning method based on the ATOS GOM measuring system, time and measurement costs depend on the methodology of measurement and the possibility of its automation. This is why the presented paper has a practical impact on possibilities for the automation of geometric accuracy measurements of obtained elements in the series production line. Social implications The use of ATOS Triple Scan II Blue Light by GOM Company allows the reduction of cost and time of production because of the possibility of the introduction of this system in an automated production line. Additionally, the measurement of hot section blades of aircraft engines by using the blue light method is much more accurate and has implication as it impacts safety of further used manufactured elements. Originality/value This paper presents the possibility of using the ATOS Triple Scan II Blue Light measuring system for geometric accuracy measurements in case of hot section blades of aircraft engines. This research is original because it describes three model geometric accuracy measurements, wax model obtained using the injection technique, wax model obtained using the I RP process and casting made of Inconel 713C nickel-based superalloy.

The analysis of precision of making elements for aeronautical dual - power path gear demonstrator applying venture baty coordinate measuring machine

The paper presents the process of measuring and analysing precision of making toothed wheels for a demonstrator of aeronautical dual-power path gear by means of FDM [2]. A coordinate measuring machine VENTURE BATY has been used in the research. The capabilities of the presented optical measuring machine make it possible to measure spur gears with different modules including small ones (m<1)which is a great advantage of this kind of measuring equipment. Analysing precision of making elements of gears is one of more important stages in creating them [6]. However, it is necessary to remember that the controlling stage should be carried out in accordance with standards concerning measuring toothed wheels defining this activity. The measuring method presented in the paper and the outcome of measurements allowed for designing a demonstrator of dual-power path gear intended for stand tests. The correct operation of a gear is assured by proper choice of constructional parameters of cooperating wheels taking into account materials used in FDM technology. The optical machine BATY is equipped with FUSION software used while measuring and analysing precision and it allows for data processing and exchanging the data with other programming environments. It is, however, restricted by one data exchange format – DXF. With regard to 2D measurement specific character, the machine does not make it possible to control tooth outline and as a consequence, it is possible to measure only gears with straight teeth. On the other hand, the advantage of the above is the possibility of comparing the measurement to CAD-2D model, which makes it possible to analyse the precision of wheels with non-standard profiles (other than envolute ones).

Quality control and inspection of bevel gears of the aircraft gearbox utilizing the ATOS 3D scanner

Quality control gears o aircraft gearbox has become a key component in today’s manufacturing process. Optical 3D scanning, based on the principle of fringe projection, has proven to be both an accurate and cost-effective alternative delivering more dimensional information to aid in quality control and process optimization by creating more meaningful measuring reports. The ATOS 3D BLUE LIGHT optical scanner has a unique capability of being user-configurable to address various measuring requirements. This is accomplished via the user’s ability to change measuring volumes in minutes, in order to increase scan data resolution or increase the measuring field of view. The paper present the opportunity to automate the measurement process of bevel gears, using coordinated optical scanner ATOS 3D “white light” version and “blue light” version. Using coordinate measuring technique, you can specify a set of methods and procedures for the designation of the complex dimensions of physical objects and transform them into a computer program space of coordinate measuring devices. The topics included in the article are intended to show the capabilities of the device used to improve the measurement process and shorten its time, and hence, lower its costs in both version of ATOS Scanner. Another thing described in the paper is the impact of measurement performance in automatic mode on the quality of performance the numerical image of scanned surface, from the standpoint of accuracy and number of collected data points in the shortest time. The article includes an analysis of conditions related to the measurement works, such as the process of preparing the model and measurement equipment and data processing capacity.

ANALYSIS OF DIMENSIONAL ACCURACY OF BLADE OF AIRCRAFT ENGINE USING A COORDINATE MEASURING MACHINE

Technological process of aircraft engine turbine blades requires control of blade geometric parameters. Innovation technologies for measurement of aircraft engine turbine blades are based on coordinate numerical machines – measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The paper presents the opportunity of analysis of dimensional accuracy of aircraft engine turbine blades measurements using coordinate measuring machine (CMM). Coordinate measuring machine allows specifying full methodology for designation of complex dimensions of physical objects (blade of aircraft engine) and transforming them into a computer program space of coordinate measuring devices. Presented paper includes capabilities of device used in the study to improve the measurement process and blades geometry analysis in the technological and economical aspects. Another issue described in the paper is impact of measurement performance in automatic mode on the quality of performance – the numerical model of geometry, from the standpoint of accuracy and number of collected data points in time. Measurements using a coordinate measuring machine are among the most accurate methods of measuring. The paper includes an analysis of conditions related to the measurement works, such as the process of preparing the model, measurement equipment and data processing capacity. As the result, methodology of (CMM) measurements of aircraft engine turbine blades will be presented.

Methodology of measurement aeronautical bevel gears using an optical scanner ATOS II Triple Scan

Properly prepared and carried out the measurement process of bevel gears determines its accuracy and productivity. This also has an influence on the final accuracy of bevel gears and the production costs of aeronautical gearbox. In the process of assessing the accuracy of manufacturing, majority of manufacturers of bevel gears use specialized contact coordinate measuring machines. The application of such machines as well as specialized programs dedicated to measuring the geometry of bevel gears are authoritative but in turns this requires substantial financial resources for the purchase of machinery. Thereby, this causes the limitation only of the gear assortment. Therefore, this article depicts different perspective on measurements of bevel gears using a universal measuring

The determination of accuracy of the demonstrator of aeronautic bevel gearbox, accomplished by selected rapid prototyping techniques using an optical scanner Atos II Triple Scan

Designing and manufacturing of aeronautic bevel gearboxes is a complicated and time-consuming process because of complex kinematics of the machining process as well as numbers of manufacturing methods. Machine manufacturers usually provide algorithms used in manufacture process. This requires substantial financial resources and, in consequence, it increases the costs of production. Using other commonly available calculation algorithm requires a lot of studies to verify whether the proposed gearbox works correctly. In order to reduce the manufacturing costs of prototypes, it is possible to use Rapid Prototyping methods. Using both Rapid Prototyping techniques and coordinate optical measurements enables to verify the correctness of assumptions made in the initial stage of product designing. This approach reduces significantly both prototyping time and manufacturing costs. In order to ensure the effectiveness of prototyping process, it is essential to provide the accuracy of manufactured prototypes. That is the reason why it is necessary to determine manufacturing methods that will ensure the highest geometric accuracy. The study presents the modelling and manufacturing process of aeronautic bevel gear of demonstrator taking into consideration the accuracy of selected Rapid Prototyping methods. The gear modelling is based on machining simulation method conducted in Autodesk Inventor. The measurement results are shown in displacement maps obtained with an optical scanner Atos II Triple Scan and universal GOM Inspect Professional software, which determines the prototype accuracy in relation to 3D-CAD models.

METHODS OF MEASUREMENT OF CYLINDRICAL GEAR AIR, GEAR WITH STANDARD SOFTWARE CMM

Air gears must meet high performance criteria for accuracy; therefore, quality control is necessary for their production. CMM Software determines the capabilities and scope of the measuring machines. Measuring machines equipped with specialized software for the measurement of the gears are commercially available. An example might be a company offering Wenzel TGEAR XY software. This specialized software for the measurement of gears allows fully automatic measurement of the contour deviation (involute), line tooth pitch, and radial run out, tooth flank topography. If you do not have a special software to measure the gear, you require a measurement process based on 3D CAD model of the gear. It is necessary in this case, the preparation of a strategy based on measurements of 3D CAD model and load points or paths with the CAD model. The results of the measurement refer to the CAD model treating it as the nominal model. Item will present the methodology of measurement of cylindrical gears using a standard CMM software. Cylindrical gears can be measured through non-contacting or contacting methods – measuring point or scanning. The choice of measurement method should be carried out taking into account the accuracy of gear and taking into account the capabilities of the system and measurement needs. An important advantage of the measurement using the gears multipurpose measuring software is that it is possible to measure any geometry of the wheels in relation to the CAD model. Using this measurement strategy avoids the need to purchase additional software, the measuring machine and its setup. You should only choose a method of analysis that will be carried out directly in the environment-measuring machine, or will be made in the CAD system based on the geometry acquired during the measurement with respect to the virtual model. In the second case, export is needed in the appropriate format measurement data to CAD software.