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CA2629219A1 - Method for producing metallic components, particularly for turbo machines, having small edge radii - Google Patents

Method for producing metallic components, particularly for turbo machines, having small edge radii Download PDF

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Publication number
CA2629219A1
CA2629219A1 CA002629219A CA2629219A CA2629219A1 CA 2629219 A1 CA2629219 A1 CA 2629219A1 CA 002629219 A CA002629219 A CA 002629219A CA 2629219 A CA2629219 A CA 2629219A CA 2629219 A1 CA2629219 A1 CA 2629219A1
Authority
CA
Canada
Prior art keywords
metallic components
producing metallic
component
accordance
shot peening
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002629219A
Other languages
French (fr)
Inventor
Thomas Dautl
Thomas Peschke
Alexander Winkler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MTU Aero Engines AG
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=37714636&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA2629219(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Individual filed Critical Individual
Publication of CA2629219A1 publication Critical patent/CA2629219A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00Making other particular articles
    • B21D53/78Making other particular articles propeller blades; turbine blades
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/10Working turbine blades or nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24CABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/08Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
    • B24C1/083Deburring
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24CABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/10Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24CABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C5/00Devices or accessories for generating abrasive blasts
    • B24C5/005Vibratory devices, e.g. for generating abrasive blasts by ultrasonic vibrations
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49316Impeller making
    • Y10T29/49336Blade making

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

The invention relates to a method for producing metallic components, particularly for turbomachines, having small edge radii, said method comprising the following steps: mechanical and/or electrochemical machining of the component and creating a small edge radius; solidifying the small edge radius by ultrasound shot peening. This avoids the disadvantages of the prior art and a mechanical, automatizable method is disclosed that permits a significant saving of time and personnel and leads to reproducible results.
The invention also relates to a component produced thereby.

Description

METHOD FOR PRODUCING METALLIC COMPONENTS, PARTICULARLY FOR TURBO
MACHINES, HAVING SMALL EDGE RADII

The invention relates to a method for producing metallic components, particularly for turbo machines, having small edge radii.

The rounding of edges on components, particularly of turbo machines, may be necessary for the most varied reasons. These include the improvement of strength and/or aerodynamics, as well as avoiding the risk of injury. Depending on the component, these may be sharp edges on components that are attached to adjacent surfaces of the component. Alternatively, the edges may also form planar or three-dimensional surfaces which connect adjacent, generally considerably larger, surfaces of the component. The last-mentioned case usually applies to relatively roughly pre-manufactured edges on flow-mechanically effective blades of turbo machines, in particular on guide vanes and rotor blades of gas turbines, in which case the blade edges must be connected to the adjacent pressure side and/or suction side of the blade in consideration of aspects of strength and aerodynamics.

Until now, the rounding of blade edges which, due to manufacturing specifics, are generally only roughly pre-machined has been done largely by manual process, usually with hand-guided machines such as belt-sanders, etc. This involves high costs regarding time and labor, whereby even targeted control and testing ultimately do not ensure a reproducible, uniform machining result. It has been known to roughen blade surfaces prior to coating operations by abrasive blasting in order to clean the surface and improve the adhesion of the layer.

From document DE 103 19 020, a method and a device for rounding edges on components, in particular of turbo machines, have been known, whereby one edge toward at least two adjacent surfaces of the component must be rounded. The center of a blast of largely abrasive particles is directed approximately tangentially to the bisector between two surfaces on the edge and moved-with defined advance-relative to the component along the edge in this way, so that a defined abrasion of the component material of the surfaces takes place during the rounding operation.

Until now, the components for turbo machines having small and minute edges or a specific geometry of the edges such as, for example, blade roots or blade profile parts, have been solidified by conventional steel shot peening. In so doing, the components must be rounded to at least an "ideal" radius of 0.3 mm.
Edges of less than 45 must be rounded at the fringes toward the component surface. In so doing, areas that are peened for solidification must be defined to be at least 0.05 mm.
Only this avoids material shifting.

In view of these known methods and their disadvantages or their technological limits in applications, it is the object of the invention to provide a method for producing metallic components, particularly for turbo machines, having small edge radii, said method permitting considerable savings of time and labor and leading to reproducible results by using a machine process that can optionally be automated. The results should be a quality that is as perfect as possible and the least possible rate of waste.

This object is achieved with the methods in accordance with the invention displaying the features of Patent Claim 1. Advantageous embodiments and developments of the invention are disclosed by the dependent claims.

In so doing, the inventive method for producing metallic components, particularly for turbo machines, having small edge radii, comprises the following steps:
Mechanical and/or electrochemical machining of a component while producing a small edge radius;
Solidifying the small edge radius by ultrasonic shot peening.
As a result of the invention, the disadvantages of the prior art are avoided and a machine process that can be automated is provided, said method permitting significant savings of time and labor and leading to reproducible results.

In particular, the method in accordance with the invention permits a stable process for the manufacture of small and minute radii and/or specific geometric configurations of the edges.
In areas that must be peened for solidification, the edge radii must be defined to be at least 0.05 mm. As a result, there is, in fact, no material shifting. Referring to the suggested method, minimum data regarding the edges or geometry of the radii is sufficient. Due to the inventive combination of the production of small and minute geometric configurations of edge radii and the unselective ultrasonic shot peening with round spheres displaying the quality of ball-bearings, a reproducible and optimal manufacturing quality is achieved.

With the use of the inventive method, small and minute radii are solidified and a cost reduction of approximately 50% is achieved, because the otherwise common manufacturing costs for producing a radius of at least 0.3 mm do not occur. In addition, process stability is substantially increased and the occurrence of material shifting is effectively prevented. Finally, considering components such as, for example, blade roots of engines, the surface percentage of the bearing surface is increased.

An advantageous development of the inventive method provides that a frequency of 18 kHz to 20 kHz be used for ultrasonic shot peening. Tests have shown that frequencies below 20 kHz are advantageous.
Another advantageous development of the inventive method provides that a vibration amplitude of 40-80 m be used with ultrasonic shot peening. Here, tests have shown that a vibration amplitude of 40 gm produces particularly good solidification results on the edge radii.

Another advantageous development of the inventive method provides that the duration of ultrasonic shot peening per peening area be 20 seconds to 30 minutes, preferably 5 minutes to 15 minutes. In so doing, the duration largely depends on the component material that is to be solidified.

Another advantageous development of the inventive method provides that a sphere size of 0.3 mm to 2 mm be used in ultrasonic shot peening. Also, in this case the selection of the sphere size is of importance with regard to the component material that is to be solidified and the size of said component.

Another advantageous development of the inventive method provides that a sphere hardness of up to 70 HRC be used in ultrasonic shot peening. This corresponds approximately to ball-bearing quality.
Another advantageous development of the inventive method provides that a ball mass of I g to 100 g per component be used in ultrasonic shot peening. However, the spheres in the housing of the ultrasonic shot peening device should not be packed too densely in order allow an appropriate vibration of the spheres.
Another advantageous development of the inventive method provides that one/more component(s) to be solidified be placed/mounted in a housing. Depending on the component, peening for the solidification of only individual sections or areas is possible.

Another advantageous development of the inventive method provides that the housing have a volume of 15 mm3 to 8 m3, preferably of I m3 to 3 m3. In so doing, the housing dimensions are a direct function of the sizes of the components.

Another advantageous development of the inventive method provides that spheres of steel, tungsten carbide, ceramic or glass be used for ultrasonic shot peening. In so doing, alloyed and unalloyed steels may be used. A ceramic material that may be used is, for example, zirconium oxide.
P806879/WO/l An inventive component for a turbo machine displays the features, namely, that the component is produced of metal and has edge radii < 0.3 mm, preferably 0.05 mm, which have been peened for solidification.

In so doing, the component edges may have different angles, e.g., 45 or 90 .
Such types of edges may be, for example, blade edges of compressor blades and/or turbine blades or also edges on blade roots. As a result of the process-stable production with the inventive method in accordance with Patent Claim 1, material shifting of the solidified areas is virtually avoided. In this case, minimum data regarding the edges or the geometric configuration of the radii is sufficient.

Additional measures that improve the invention are stated in the subclaims and are hereinafter explained in greater detail, together with the description of a preferred exemplary embodiment of the invention and with reference to the drawings. They show in:

Fig. 1 a flowchart of a first embodiment of a method in accordance with the invention.
Figure I shows a flowchart of a first embodiment of an inventive method which uses a metallic component for machining. In particular considering blades of turbo machines, high-quality alloys, e.g., nickel-based alloys, are used. Further, these blade components frequently have so-called fur-tree blade roots with several edges. In accordance with the invention, the component is initially machined, for example, machined down, or ground or treated electrochemically, for example, by an erosion process. In so doing, corresponding edges are produced or reworked.

During the next method step, the component is transferred to an ultrasonic shot peening station. The component, depending on its size, is placed in a housing having a size of 15 mm3 to 8 m3. Then the minute radii of 0.05 mm are solidified by ultrasonic shot peening. The peening process lasts approximately I minute to 5 minutes. Referring to the described ultrasonic shot peening, a piezoelectric transducer emits ultrasonic waves with an adjustable frequency of 18 kHz to 20 kHz. The housing of the ultrasonic shoot peening devices contains, in addition to the component, ideal steel spheres, i.e., spheres displaying ball-bearing quality and a hardness of approximately 70 HRC, and a sphere size of 0.3 mm to 2 mm. The sound waves are amplified when they pass through an acoustic amplifier in a housing with the components to be processed and with the ball-bearing spheres. The spheres that are excited by the ultrasound waves with a vibration wave of 40 m impinge on the vibrating walls and are reflected by said walls' surfaces. The spheres collide with each other and are scattered in an unordered manner like gas molecules in the housing. As a result of this, a reproducible homogeneous solidification of the edges and radii is achieved. In so doing, the components themselves do not come into contact with the housing walls.

Consequently, a component with minute solidified edge radii of 0.05 mm is produced. Considering the blade roots of engines, the percentage of the bearing surface is thus increased considerably.

In principle, the method in accordance with the invention can be used with all types of components and, in particular, with turbo machine blades, be it housings, disks, rings, compressors, pumps and turbines in axial, diagonal and radial construction.

***

Claims (11)

1. Method for producing metallic components, particularly for turbo machines, having small edge radii, said method comprising the following steps:
Mechanical and/or electrochemical machining of a component while producing a small edge radius;
Solidifying the small edge radius by ultrasonic shot peening.
2. Method for producing metallic components in accordance with patent claim 1, whereby a frequency of 18 kHz to 20 kHz is used for ultrasonic shot peening.
3. Method for producing metallic components in accordance with patent claim 1, whereby a vibration amplitude of 40-80 µm is used for ultrasonic shot peening.
4. Method for producing metallic components in accordance with patent claim 1, whereby the duration of ultrasonic shot peening per peening area is 20 seconds to 30 minutes, preferably 5 minutes to 15 minutes.
5. Method for producing metallic components in accordance with patent claim 1, whereby a sphere size from 0.3 mm to 2 mm is used for ultrasonic shot peening.
6. Method for producing metallic components in accordance with patent claim 1, whereby a sphere hardness of up to 70 HRC is used for ultrasonic shot peening.
7. Method for producing metallic components in accordance with patent claim 1, whereby a sphere mass of 1 g to 100 g per component is used in ultrasonic shot peening.
8. Method for producing metallic components in accordance with patent claim 1, whereby one/more component(s) to be solidified are placed/mounted in a housing.
9. Method for producing metallic components in accordance with patent claim 1, whereby the housing has a volume of 15 mm3 to 8 m3, preferably from 1 m3 to 3 m3.
10. Method for producing metallic components in accordance with patent claim 1, whereby spheres consisting of steel, tungsten carbide, ceramic or glass are used for ultrasonic shot peening.
11. Component for a turbo machine, in which case the component is produced of metal and has edge radii < 0.3 mm, preferably 0.05 mm, said edge radii having been solidified by peening.
CA002629219A 2005-11-17 2006-11-10 Method for producing metallic components, particularly for turbo machines, having small edge radii Abandoned CA2629219A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102005054866A DE102005054866A1 (en) 2005-11-17 2005-11-17 Method for producing metallic components, in particular for turbomachinery, with small edge radii
DE102005054866.0 2005-11-17
PCT/DE2006/001972 WO2007056978A1 (en) 2005-11-17 2006-11-10 Method for producing metallic components, particularly for turbo machines, having small edge radii, and component produced therewith

Publications (1)

Publication Number Publication Date
CA2629219A1 true CA2629219A1 (en) 2007-05-24

Family

ID=37714636

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002629219A Abandoned CA2629219A1 (en) 2005-11-17 2006-11-10 Method for producing metallic components, particularly for turbo machines, having small edge radii

Country Status (6)

Country Link
US (1) US20090044406A1 (en)
EP (1) EP1954421B2 (en)
CA (1) CA2629219A1 (en)
DE (1) DE102005054866A1 (en)
PL (1) PL1954421T5 (en)
WO (1) WO2007056978A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008008894A1 (en) * 2008-02-13 2009-08-20 Man Turbo Ag Method for producing a component for a thermal machine
FR2930184B1 (en) * 2008-04-18 2010-12-31 Snecma PROCESS FOR ULTRASONIC CRUSHING OF TURBOMACHINE PARTS.
FR3061055B1 (en) * 2016-12-26 2019-07-26 Safran Aircraft Engines DEVICE FOR PROCESSING A METAL PIECE, METHOD AND ASSEMBLY OF PROJECTILES THEREFOR
CN110421489B (en) * 2019-08-14 2023-12-15 苏州科技大学 Focused ultrasonic abrasive jet flow composite polishing device and method

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4426867A (en) 1981-09-10 1984-01-24 United Technologies Corporation Method of peening airfoils and thin edged workpieces
FR2791293B1 (en) * 1999-03-23 2001-05-18 Sonats Soc Des Nouvelles Appli IMPACT SURFACE TREATMENT DEVICES
FR2801236B1 (en) * 1999-11-18 2001-12-21 Snecma METHOD AND MACHINE FOR ULTRASONIC BLASTING OF WORKPIECES ON A WHEEL
FR2801322B1 (en) 1999-11-18 2002-02-08 Snecma METHOD FOR ULTRASONIC BLASTING OF LARGE DIMENSIONAL ANNULAR SURFACES ON THIN PARTS
FR2816538B1 (en) * 2000-11-16 2003-01-17 Snecma Moteurs PROCESS FOR INCREASING THE LIFETIME OF AUB ATTACHES ON A ROTOR
JP4189201B2 (en) * 2002-10-30 2008-12-03 新日本製鐵株式会社 Method for improving toughness of heat-affected zone in steel welded joints
DE10258920A1 (en) 2002-12-17 2004-07-01 Rolls-Royce Deutschland Ltd & Co Kg Method and device for shaping by electrochemical removal
DE10319020B4 (en) * 2003-04-27 2006-06-14 Mtu Aero Engines Gmbh Method of rounding edges on blades of turbomachinery
FR2873609B1 (en) * 2004-07-30 2008-02-22 Sonats Soc Des Nouvelles Appli PROJECTILES, DEVICES AND ULTRASONIC SCRATCHING DEVICES AND PARTS THUS PROCESSED
US20060021410A1 (en) * 2004-07-30 2006-02-02 Sonats-Societe Des Nouvelles Applications Des Techniques De Surfaces Shot, devices, and installations for ultrasonic peening, and parts treated thereby
FR2907360B1 (en) * 2006-10-20 2009-05-22 Sonats Soc Des Nouvelles Appli METHODS AND INSTALLATIONS OF SCRATCHES.

Also Published As

Publication number Publication date
PL1954421T5 (en) 2017-07-31
DE102005054866A1 (en) 2007-05-31
PL1954421T3 (en) 2011-11-30
WO2007056978A1 (en) 2007-05-24
EP1954421A1 (en) 2008-08-13
EP1954421B2 (en) 2016-07-13
EP1954421B1 (en) 2011-06-15
US20090044406A1 (en) 2009-02-19

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Legal Events

Date Code Title Description
FZDE Discontinued

Effective date: 20121113