Pawel Rokicki, Grzegorz Budzik, Krzysztof Kubiak, Tomasz Dziubek, Malgorzata Zaborniak, Bogdan Kozik, Jacek Bernaczek, Lukasz Przeszlowski and Andrzej Nowotnik
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…
Abstract
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, Rzeszów 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.
Details
Keywords
Paweł Rokicki, Grzegorz Budzik, Krzysztof Kubiak, Jacek Bernaczek, Tomasz Dziubek, Marek Magniszewski, Andrzej Nowotnik, Jan Sieniawski, Hubert Matysiak, Rafał Cygan and Andrzej Trojan
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…
Abstract
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.
Details
Keywords
Maria Dems, Krzysztof Komeza, Jacek Szulakowski and Witold Kubiak
The purpose of this paper is to present the application of the loss approximation method for non-oriented electrical steel developed by the authors. A new model of a toroidal…
Abstract
Purpose
The purpose of this paper is to present the application of the loss approximation method for non-oriented electrical steel developed by the authors. A new model of a toroidal sample with dimensions ensuring high uniformity of the field was presented.
Design/methodology/approach
A critical analysis of the methods used was carried out. Based on these considerations, the authors proposed their own loss approximation method, which allows obtaining high accuracy in a wide range of induction and frequency. The proposed method is based on the assumption that for a certain frequency range losses can be describe by two terms formula. For a fixed value of the peak flux density Bm, the graph of specific loss divided by the frequency should have the form of a straight line. Then, the obtained coefficients for different Bm are the basis for approximation with the power function.
Findings
The comparison of measurement and approximation results shows that the method allows to obtain very good accuracy in a wide range of induction and frequency.
Research limitations/implications
More detailed studies on the impact of cutting on a larger number of samples with different geometrical dimensions are needed.
Practical implications
Application of the new method provides a better approximation of the curve of the loss and thus a more accurate calculation of the core loss in the electrical machines.
Originality/value
The paper presents the application of the loss approximation method for non-oriented electrical steel developed by the authors. A new model of a toroidal sample with dimensions ensuring high uniformity of the field was presented. It is shown that the approximation introduced allows for high accuracy in a wide range of frequency and magnetic flux density.
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Keywords
Patryk Adam Jakubczak, Jaroslaw Bienias, Radoslaw Mania and Krzysztof Majerski
The purpose of the study was to develop the forming methodology for FML laminates with complex shapes, based on aluminium and epoxy-glass composite.
Abstract
Purpose
The purpose of the study was to develop the forming methodology for FML laminates with complex shapes, based on aluminium and epoxy-glass composite.
Design/methodology/approach
The subject of research encompassed Al/GFRP fibre metal laminates. Autoclave process has been selected for FML profiles production. The manufacturing process was followed by quality analysis for laminates produced.
Findings
The achievement of high stability and dimensional tolerance of thin-walled FML laminates is ensured by developed technology. The values of selected sections angles are significantly limited as a result of forming of FML laminates through the components performing. Failure to adhere to technological recommendations and to high regime of developer technology may lead to the occurrence of defects in FML.
Practical implications
Thin-walled composite structures could be applied in light-weight constructions, such as aircraft structures, which must meet rigorous requirements with regard to operation under complex load. The development of this type of technology may contribute to increased importance of FML sections in research area and finally to increased scope of their applications.
Originality/value
The production of thin-walled FML profiles with complex geometry, which would be characterized by dimensional stability and repeatable structural quality free of defects, is associated with many problems. No studies have been published so far on an effective forming process for FML laminates with complex shapes. Developed methodology has been verified through quality evaluation of produced profiles by means of non-destructive and destructive methods. The development of this type of technology may contribute to increased importance of FML, e.g. in aerospace technology.