U.S. patent application number 13/823698 was filed with the patent office on 2013-08-22 for method for the production of a one-piece rotor area and one-piece rotor area.
This patent application is currently assigned to ROLLS-ROYCE DEUTSCHLAND LTD & CO KG. The applicant listed for this patent is Goetz G. Feldmann. Invention is credited to Goetz G. Feldmann.
Application Number | 20130216391 13/823698 |
Document ID | / |
Family ID | 45992234 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130216391 |
Kind Code |
A1 |
Feldmann; Goetz G. |
August 22, 2013 |
METHOD FOR THE PRODUCTION OF A ONE-PIECE ROTOR AREA AND ONE-PIECE
ROTOR AREA
Abstract
The present invention describes a method for the production of a
one-piece rotor area, preferably of a jet engine. The rotor area
includes an annular base body and several, circumferentially
distributed blade elements extending essentially radially from the
base body. Residual stresses are imparted to the blade elements in
surface-near areas by way of roller compression using a rolling
tool introduced between the blade elements. During roller
compression, one each area of a blade element is arranged between
areas of the rolling tool, with longitudinal sides of the blade
element being simultaneously roller-compressed. According to the
present invention, the rolling tool is radially introduced between
the blade elements and the surfaces of the blade elements are
roller-compressed, thus at least the blade elements having a
roller-compressed surface.
Inventors: |
Feldmann; Goetz G.;
(Oberursel, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Feldmann; Goetz G. |
Oberursel |
|
DE |
|
|
Assignee: |
ROLLS-ROYCE DEUTSCHLAND LTD &
CO KG
Blankenfelde-Mahlow
DE
|
Family ID: |
45992234 |
Appl. No.: |
13/823698 |
Filed: |
April 12, 2012 |
PCT Filed: |
April 12, 2012 |
PCT NO: |
PCT/EP12/56612 |
371 Date: |
April 30, 2013 |
Current U.S.
Class: |
416/241R ;
29/889.6 |
Current CPC
Class: |
F01D 5/147 20130101;
Y02T 50/673 20130101; B23P 9/02 20130101; F01D 5/02 20130101; Y10T
29/49332 20150115; Y02T 50/60 20130101; F05D 2230/26 20130101; B24B
39/04 20130101; Y02T 50/671 20130101; C21D 7/08 20130101 |
Class at
Publication: |
416/241.R ;
29/889.6 |
International
Class: |
F01D 5/14 20060101
F01D005/14 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 12, 2011 |
DE |
10 2011 007 224.1 |
Claims
1. Method for the production of a one-piece rotor area, preferably
a rotor area of a jet engine, with the rotor area including an
annular base body and several, circumferentially distributed blade
elements extending essentially radially from the base body, with
residual stresses being imparted to the blade elements in
surface-near areas by way of roller compression using a rolling
tool introduced between the blade elements, with one each area of a
blade element being arranged between areas of the rolling tool
during roller compression, and with longitudinal sides of the blade
element being simultaneously roller-compressed, characterized in
that the rolling tool is radially introduced between the blade
elements and the surfaces of the blade elements are
roller-compressed.
2. Method in accordance with claim 1, characterized in that the
surfaces of the blade elements are roller-compressed by sequential
radial traversing at least in certain areas.
3. Method in accordance with claim 1, characterized in that the
surfaces of the blade elements are roller-compressed by sequential
axial traversing at least in certain areas.
4. Method in accordance with claim 1, characterized in that the
surfaces of the blade elements are roller-compressed by arbitrarily
moving the rolling tool along the surfaces of the blade elements at
least in certain areas.
5. Method in accordance with claim 1, characterized in that the
transition areas between the surfaces of the blade elements and the
surface of the base body between the blade elements are
roller-compressed using a rolling tool.
6. Method in accordance with claim 1, characterized in that the
surface of the base body between the blade elements is
roller-compressed using a rolling tool.
7. Method in accordance with claim 1, characterized in that the
surfaces of several blade elements axially arranged one behind the
other are roller-compressed.
8. Method in accordance with claim 1, characterized in that a
rolling force for setting a residual stress profile on the surfaces
of the blade elements and/or the transition areas and/or the
surface of the base body is variable between the blade
elements.
9. One-piece rotor area with an annular base body and several blade
elements distributed over the circumference of the base body and
extending essentially radially from the base body, characterized in
that at least the blade elements feature a roller-compressed
surface.
10. One-piece rotor area in accordance with claim 9, characterized
in that the transition areas between the surfaces of the blade
elements and the surface of the base body between the blade
elements feature a roller-compressed surface.
11. One-piece rotor area in accordance with claim 9, characterized
in that the base body features a roller-compressed surface at least
in the area between the blade elements.
12. One-piece rotor area in accordance with claim 9, characterized
in that several blade elements axially arranged one behind the
other on the base body are provided with a roller-compressed
surface.
Description
[0001] This invention relates to a method for the production of a
one-piece rotor area according to the type more precisely defined
in the generic part of patent claim 1 as well as to a one-piece
rotor area according to the type more precisely defined in the
generic part of patent claim 9.
[0002] Downstream of a fan, jet engines known from practical
applications are provided with multi-stage compressors, in the area
of which the core airflow is incrementally increased to a desired
pressure level. The individual compressor stages include blade
elements or rotor blades of one-piece rotor areas rotating during
the operation of a jet engine and vane elements or stationary guide
vanes corresponding therewith.
[0003] In the area of the non-rotating stators, mechanical loading
is relatively low during the operation of a jet engine since, on
the one hand, rotation-due centrifugal loads do not exist and, on
the other hand, blade vibrations are minimized by the residual
stress of the flow profile in the root and top area.
[0004] However, high mechanical loading is present during the
operation of a jet engine in the area of the rotor blades. Their
total load is composed of several partial loads, with the
centrifugal force being the dominant partial load. Since the change
of speed is only small during the operation of a jet engine, the
centrifugal force, which is superimposed by dynamic partial loads,
can be considered as approximately static.
[0005] The dynamic partial loads result from the rotation-due
vibration excitation of the rotor blades or the blade elements,
respectively. Furthermore, the rotor blades are subject to
aerodynamically caused loads which are primarily attributable to
periodically non-stationary flows. Generally, periodically
non-stationary flows are due to the stator-rotor interaction
generated by the splitting of the flow as the rotor blades pass the
stator vanes. Dynamic loads are further produced by interaction of
the flow profiles with the turbulent flow, again resulting in blade
vibrations. The dynamic partial loads, in total, lead to
high-frequency vibrations occurring in operation primarily in the
area of rotor blades of compressors as well as fans or, generally
speaking, one-piece rotor areas of jet engines, resulting in highly
dynamic stressing of the rotor blades.
[0006] Besides mechanical loading, part of the blades is also
subject to thermal loading. This applies primarily to the blades of
the high-pressure compressor and the rearward blades of the
low-pressure compressor where operating temperatures up to
600.degree. C. exist.
[0007] Generally, the blades of compressors or fans of jet engines
are designed such that the fatigue strength is not, or only in a
defined manner, exceeded by the dynamic operating loads and
endurance strength or, respectively, a defined level of fatigue
strength is ensured. However, premature crack initiation and
sometimes even uncontrolled failure of fan and compressor blades,
which is predominantly attributable to blade damage by foreign
objects, are encountered time and again.
[0008] Such foreign object damage is impact damage resulting from
the impingement of hard foreign objects. The foreign objects are
generally stones and fragments of bolts, nuts, washers and similar
items lying on the runway.
[0009] Foreign objects frequently fragment upon impingement. These
fragments, as well as any object passing the fan area without
collision, are entrained further into the engine by the airflow. If
the engine features a large bypass airflow, part of the objects may
leave the engine via said bypass airflow without causing any major
damage. The other part enters the low-pressure compressor together
with the core airflow, causing serious collision, primarily with
the quickly rotating rotor blades. As a result of kinematics, the
main damage location is, similar to the fan, in the area of the
inflow edge and the forward concave profile side.
[0010] In order to protect the blade elements or, respectively, the
rotor blades against foreign object damage and avoid any crack
formation resulting therefrom in the area of the blades during the
operation of the engine, it is required that the blade elements, as
well as the annular base bodies forming an integral part thereof be
conceived with suitable solidity. The high material investment
involved therewith however increases the total weight and also the
manufacturing costs of a jet engine in an undesirable manner.
[0011] Therefore, a method of resolidifying rotor blades or blade
elements, respectively, of jet engines has been adopted, using
appropriate manufacturing processes, and enabling rotor blades to
be provided whose component dimensions are smaller than those of
non-resolidified rotor blades.
[0012] For this purpose, the rotor blades and annular base bodies
forming an integral part of the rotor blades are resolidified by
means of shot peening, with residual stresses being produced in the
shot-peening process in surface-near areas of the rotor blades
counteracting crack formation and crack propagation due to foreign
object damage or vibratory loading to the extent required.
[0013] It is however disadvantageous that the surfaces of rotor
blades resolidified by shot peening have inferior surface quality
which must be re-improved after shot peening by elaborate and
costly rework operations. Moreover, shot peening does not ensure a
uniform processing of rotor blades or blade elements, respectively,
of one-piece rotor areas, since--for example due to ricochetting or
shielding effects--some surface areas are hit by the shot more
frequently than others, as a result of which effects detrimental to
service life, such as de-solidification, may occur and reproducible
processing results are not ensured. Solidification of one-piece
rotor areas by means of shot peening is therefore very imprecise
and also cost-intensive as it involves the use of compressed
air.
[0014] It is further known to roll rotor blades in certain areas by
means of pliers-type tooling, thereby generating residual stresses
in surface-near areas of the rotor blades. In the process, a blade
area facing the flow is solidified by roller compression using a
rolling tool in the direction of flow or in the axial direction,
respectively. Here, usually approx. 20 percent of the surface of a
blade element are roller-compressed by simultaneous, both-side
rolling of the longitudinal sides in the direction of flow,
starting at the leading edge of the blade element, thereby
achieving or retaining a high surface quality and avoiding
deformation of thin-walled profiles.
[0015] This process is, however, disadvantageous in that stress
jumps occur at the transition between the surface area of a blade
element resolidified by roller compression and the non-resolidified
surface area of a blade element. As the blade element is subject to
vibratory loads, maximum stress limits are exceeded at this
transition area so that plastic flow occurs in the area between the
processed area of a blade element and the surface area not
processed by roller compression which may result in undesirable
crack formation. Cracks once produced will propagate under further
vibratory load, ultimately leading to the failure of a blade
element.
[0016] The present invention, in a broad aspect, provides a method
for the production of a one-piece rotor area, preferably of a jet
engine, by means of which one-piece rotor areas are producible with
high resistance to foreign object damage and vibratory loading and
at the same time low component weight. In addition, it is an object
of the present invention to provide a one-piece rotor area which,
while being cost-effectively producible and having a surface with
low roughness, is characterized by high resistance to foreign
object damage and vibratory loading.
[0017] It is a particular object of the present invention to
provide solution to the above problematics by a method in
accordance with the features of patent claim 1 and a one-piece
rotor area in accordance with the features of patent claim 9.
[0018] In the method according to the present invention for the
production of a one-piece rotor area, preferably of a jet engine,
including an annular base body and several, circumferentially
distributed blade elements extending essentially radially from the
base body, residual stresses are imparted to the blade elements in
surface-near areas by way of roller compression using a rolling
tool introduced between the blade elements. During roller
compression, one each area of a blade element is arranged between
areas of the rolling tool, with longitudinal sides of the blade
element being simultaneously roller-compressed.
[0019] According to the present invention, the rolling tool is
radially introduced between the blade elements and the surfaces of
the blade elements are roller-compressed.
[0020] Roller compression of the surfaces of the blade elements
enables a one-piece rotor area, preferably of a jet engine,
including an annular base body and several, circumferentially
distributed blade elements, to be provided with--as compared to
non-resolidified rotor areas--lower material investment and, thus,
lower total weight while at the same time having equal or higher
resistance to foreign object damage and vibratory loading.
[0021] Moreover, roller compression of the surfaces of the blade
elements provides a simple means of avoiding stress jumps and
improving the resistance to vibratory loading as compared to blade
elements that are resolidified only in certain areas.
[0022] As the rolling tool is introduced radially between the blade
elements, high resistance to foreign object damage and vibratory
loading can easily also be provided to one-piece rotor areas having
several blade elements arranged axially one behind the other on the
base body. Because of the small spacing between the individual
blade element rows, this is not possible using the known practices
in which the rolling tool is axially introduced between the blade
elements.
[0023] In a variant of the method according to the present
invention characterized by low control effort, the surfaces of the
blade elements are roller-compressed by sequential radial
traversing, at least in certain areas.
[0024] In a variant of the method according to the present
invention, which is also easily feasible, the surfaces of the blade
elements are rolled by sequential axial traversing, at least in
certain areas.
[0025] If the surfaces of the blade elements are roller-compressed
by arbitrarily moving the rolling tool along the surfaces of the
blade elements at least in certain areas, the latter can be
provided with a surface structure required for generating a
homogenous flow around the blade elements.
[0026] In a further advantageous variant of the method according to
the present invention, resistance of a one-piece rotor area is
further increased in that the transition areas between the surfaces
of the blade elements and the surface of the base body between the
blade elements is roller-compressed using a rolling tool.
[0027] Resistance to foreign object damage and vibratory loading of
a one-piece rotor area characterized by low weight can further be
improved in that the surface of the base body between the blade
elements is roller-compressed using a rolling tool.
[0028] In order to further improve durability of the blade
elements, a further advantageous variant of the method according to
the present invention provides that a rolling force is variable to
enable the surfaces of the blade elements to be provided with
specifically the surface-near residual compressive stress which in
each case is best for increasing the resistance to foreign object
damage and vibratory loading.
[0029] The one-piece rotor area according to the present invention
features an annular base body and several blade elements
distributed over the circumference of the base body and extending
essentially radially from the latter. Since at least the blade
elements have a roller-compressed surface, the one-piece rotor area
according to the present invention--as compared to non-resolidified
or only partly resolidified one-piece rotor areas--is characterized
by low weight while at the same time having at least equal
resistance to foreign object damage and vibratory loading and,
additionally, provided in the area of the blade elements in a
cost-effective manner, as no extra processing steps are required,
with a surface characterized by high surface finish supporting
homogenous flow around the blade elements.
[0030] If also the joining areas between the surfaces of the blade
elements and a surface of the base body are provided with a
roller-compressed surface, both resistance to foreign body damage
and vibratory loading as well as homogenous flow around the
one-piece rotor area are ensured.
[0031] In another advantageous embodiment of the one-piece rotor
area in accordance with the present invention, resistance to
foreign object damage and vibratory loading is improved in that the
base body features a roller-compressed surface at least in the area
between the blade elements.
[0032] In a further advantageous embodiment of the one-piece rotor
area, several blade elements axially arranged one behind the other
on the base body are provided with a roller-compressed surface.
[0033] Both the features cited in the patent Claims and the
features specified in the following exemplary embodiment of the
subject matter of the present invention are, alone or in any
combination, capable of further developing the subject matter of
the present invention. The respective combinations of features are
in now way limiting the development of the subject matter of the
present invention, but essentially have only exemplary
character.
[0034] Further advantages and advantageous embodiments of the
subject matter of the present invention become apparent from the
patent Claims and the exemplary embodiment schematically described
in the following with reference to the accompanying drawing. In the
drawing,
[0035] FIG. 1 shows a highly schematized longitudinal sectional
view of a jet engine provided with a one-piece rotor area,
[0036] FIG. 2 is an enlarged individual representation of a blade
element of the one-piece rotor area as per FIG. 1,
[0037] FIG. 3 is a side view of a rolling tool, and
[0038] FIG. 4 shows the rolling tool as per FIG. 3 in a view IV
represented in more detail in FIG. 3.
[0039] FIG. 1 shows a longitudinal sectional view of a jet engine 1
provided with a bypass duct 2. The jet engine 1 is further provided
with an inlet area 3 downstream of which a fan 4 is arranged in
known manner. Again downstream of the fan 4, the fluid flow in the
jet engine 1 divides into a bypass flow and a core flow, with the
bypass flow passing through the bypass duct 2 and the core flow
into an engine core 5 which, again in known manner, is provided
with a compressor arrangement 6, a burner 7 and a turbine
arrangement 8.
[0040] FIG. 2 shows an enlarged individual view of a one-piece
rotor area 9 of the compressor arrangement 6 including an annular
base body 10 and several circumferentially distributed blade
elements 11 extending essentially radially from the base body
10.
[0041] The one-piece rotor area 9 is a so-called blisk, i.e. an
integrally bladed rotor design. The term blisk is composed of the
words "blade" and "disk". The disk or, respectively, the annular
base body 10 and the blade elements 11 are made in one-piece,
removing the need for blade roots and disk slots provided on
multi-piece rotor areas. The one-piece rotor area 9 is distinct
from conventionally bladed compressor rotors by a significant
decrease in the number of components and the disk shape of the
annular base body 10 is designed for lower rim loads. In
combination with the use of lighter materials, this results in a
weight saving of the one-piece rotor area 9 of up to 50 percent
compared to conventional rotor areas. The amount of weight saving
is in each case dependent on the geometry of the compressor
arrangement 6.
[0042] A further positive effect is that the blade elements 11 of
the integrally bladed rotor area 9 are spaceable more closely to
each other, thereby enabling best possible compression and
enhancement of efficiency.
[0043] In order to provide the compressor arrangement 6 or,
respectively, the one-piece rotor area 9 with resistance to foreign
object damage and also vibratory loading while at the same time
keeping the weight low, residual stresses are imparted to the blade
elements 11 in surface-near areas by way of roller compression
using a rolling tool 14 radially engaging in each case between the
blade elements 11 and further shown in FIGS. 3 and 4, with the
entire surface of each blade element 11 being roller-compressed in
each case. Additionally, the transition areas 12, or fillets,
respectively, between the surfaces of the blade elements 11 and a
surface 13 of the base body 10 between the blade elements 11 are
also roller-compressed by means of a so-called one-finger rolling
tool not further shown in the drawing.
[0044] Furthermore, the surface 13 or, respectively, the annulus of
the base body 10 between the blade elements 11 is preferably also
roller-compressed by means of a one-finger rolling tool.
[0045] Roller-compressing the surfaces of the longitudinal sides
and the edges of the blade elements 11, the transition areas 12 and
the surface 13 of the base body 10 in each case solidifies
surface-near areas of the one-piece rotor area 9 by increasing
dislocation density and hardens the surface layer of the rotor area
9. Hardening the surface layer reduces the risk of cracking
resulting from foreign object damage and vibratory loading.
Moreover, the residual compressive stresses imparted by roller
compression to the material in the area of the rotor area 9
counteract crack propagation after crack formation, thereby
positively influencing fatigue strength and, thus, the service life
of the jet engine 1.
[0046] Furthermore, roller compression provides the one-piece rotor
area 9 with high surface finish and low surface roughness, thereby
positively influencing the aerodynamic quality of the blade
elements 11 and the entire rotor area 9 without the need for a
further surface smoothening process to be performed subsequently to
the solidification process.
[0047] FIG. 3 and FIG. 4 each show a side view of a rolling tool 14
for roller-compressing the longitudinal sides or, respectively, the
entire surface of the blade elements 11 of the rotor area 9. The
rolling tool 14 includes a tool carrier 15, which can be connected
to a carrier spindle 16 of a machine tool to the extent shown. Two
pliers-type bodies 17, 18 of the rolling tool 14 are rotatably
connected to the tool carrier 15 in the area of a rotating bearing
19, with the pliers-type bodies 17, 18 being coupled via a driving
unit 20 provided here as single-acting piston-cylinder unit and a
distance between rolling areas 21, 22 being reduced in dependence
of a driving unit-side rotational movement of the pliers-type
bodies 17 and 18 about the rotating bearing 19. For this, the
driving unit 20 is subject to hydraulic pressure and, under the
action thereof, a piston element 23 is extended from a cylinder
element 24 of the driving unit 20, with a distance between the ends
25 and 26 of the pliers-type bodies 17 and 18 facing away from the
rolling areas 21 and 22 being increased during such a change of the
operating state of the driving unit 20, while the distance between
the rolling areas 21 and 22 is decreased according to the geometric
situation in dependence of the rotary movement of the pliers-type
bodies 17 and 18 about the rotating bearing 19. The pliers-type
bodies 17 and 18 are each rotatably connected to the driving unit
20 in the area of their ends 25 and 26.
[0048] Furthermore, the two pliers-type bodies 17 and 18 are
additionally rotatably attached to the tool carrier 15 around the
rotating bearing 19 about a rotary axis 27 vertically aligned to
the drawing plane to enable the pliers-type bodies 17 and 18 to be
swivelled upon contact of the rolling areas 21 and 22 with a blade
element 11 and avoid distortion of the blade elements 11 resulting
from the contact of the rolling areas 21 and 22 with the blade
element. During joint rotation of the pliers-type bodies 17 and 18
around the rotating bearing 19 relative to the tool carrier 15, the
distance between the rolling areas 21 and 22 remains constant.
Joint rotatability of the two pliers-type bodies 17 and 18 around
the rotating bearing 19 further ensures that the blade elements 11,
each of which being provided with a blade profile, are
roller-compressible on their entire surface using the rolling tool
14.
[0049] The pliers-type bodies 17 and 18 are operatively connected
to the tool carrier 15 via piston elements 28 and 29, with the
piston elements 28 and 29 resetting the pliers-type bodies 17 and
18 relative to the tool carrier 15 around the rotating bearing 19
to a zero position defined relative to the tool carrier 15 and
shown in FIG. 3 when a rotating force jointly rotating the
pliers-type bodies 17 and 18 around the rotating bearing 19 is
essentially zero.
[0050] Furthermore, a resetting device 32, here including two
spring-action devices 30 and 31, is associated to the pliers-type
bodies 17 and 18 through which the latter are rotated to enable a
distance between the rolling areas 21 and 22 to be changed to a
maximum value.
[0051] Each of the rolling areas 21 and 22 here includes a ball
element 33, 34 retained in holding areas each and subjectable to
hydraulic pressure in known manner to enable the rolling pressure
required in each case to be applied to the blade elements 11 via
the ball elements 33 and 34.
[0052] The holding areas 35 and 36 are here inserted into, and
threadedly connected, preferably by means of grub screws, to
adapter elements 37 and 38 which are firmly threadedly connected to
the pliers-type bodies 17 and 18 and are at least approximately
finger-shaped.
[0053] Each of the adapter elements 37 and 38 is changeable so that
the rolling tool 14 provides for various engagement depths in the
radial direction between the blade elements 11. Moreover, adapter
elements 37 and 38 designed with respect to the transmittable
pressure or rolling force, respectively, are connectable to the
pliers-type bodies 17 and 18, with thinner adapter elements being
insertable into narrower areas between the blade elements 11. Here,
lower rolling or pressure forces, respectively, are applied to
thinner blade elements 11 with more slender adapter elements 37 and
38, with the adapter elements 37 and 38 then having a certain
elasticity and the maximum rolling force being limited by the
elasticity of the adapter elements 37 and 38. Full solidification
of the blade elements during compression rolling is avoidable by
limiting the maximum rolling force, with excessive pressure loading
during roller compression producing a tensile stress maximum in the
center area of the blade elements 11 which promotes internal crack
formation under vibratory loading. This, however, is undesirable as
it affects the service life of the blade elements 11.
[0054] The rolling force imparted in each case to the rotor area
during roller compression is variable at each location of a blade
element 11 and also in the transition areas 12 and the remaining
surface 13 of the base body 10 by controlling the hydraulic
pressure applied to the rolling areas 21, 22 via a pressure control
unit not further shown in the drawing, thereby enabling the rotor
area 9 to be solidified to the desired extent by producing the
optimum residual compressive stresses required at each location of
the rotor area 9 and an improvement to be obtained with regard to
the durability of the blades.
[0055] In order to facilitate, for example, CAD-CAM programming
upstream of a roller compression process using the rolling tool 14
and subsequent implementation of the manufacturing programs on a
multi-axes machining center by means of a post processor, an axis
39 of the carrier spindle 16 in the operating state connected to
the tool carrier 15 passes between the rolling areas 21 and 22
through a contact point present at a distance between the rolling
areas 21 and 22 equal to zero. Thus, the axis or the spindle
carrier axis 29, respectively, and an axis through the contact
point between the rolling areas 21 and 22 are congruent, thereby
substantially facilitating programming.
[0056] In order to avoid damage to the blade elements 11 to be
processed and to the rolling tool 14 proper, a distance between the
rolling areas 21 and 22 is reducible via the drive unit 20 no
further than to a defined limit value. Since the two ball elements
33 and 34 cannot be brought into contact with each other by
respective turning or swivelling of the pliers-type bodies 17 and
18 and, thus, the adapter elements 37 and 38, damage to the rolling
tool 14 is prevented in a simple manner.
[0057] The rolling tool 14 enables integrally bladed disks and
rotors of jet engines to be roller-compressed at low cost. The
rapid and easy exchange of the adapter elements 37 and 38 qualifies
the rolling tool 14 with low setup times for use with rotor areas
having different geometry, with different engagement depths between
blade elements as well as different processing forces during the
rolling process being representable on differently conceived
components with high safety and process capability.
[0058] The pliers-type design of the rolling tool 14 enables blade
elements or airfoils, respectively, of one-piece rotor areas to be
processed from the tip to the fillet, with simultaneous roller
compression of the pressure and suction sides of blade elements
being provided to avoid distortion due to residual stress.
[0059] In addition, various individual tools enable the fillets or
the transition areas, respectively, between the surface of the
blade elements and the surface of the base body between the blade
elements on the suction and pressure side to be processed to the
desired extent. Moreover, the surface of the base body between the
blade elements or the annulus, respectively, is roller-compressible
by means of individual tools.
[0060] Basically, the rolling tool 14 can be integrated into any
known machining center. In contrast to resolidification by shot
peening, there is no need to procure expensive facilities. The
rolling tool 14 enables resolidification to be performed, for
example, in conventional milling centers. The milling centers are
equipped with the rolling tool 14 and the one-piece rotor areas are
processed using the rolling tool 14 in the area of their surfaces
analogically to milling.
LIST OF REFERENCE NUMERALS
[0061] 1 Jet engine [0062] 2 Bypass duct [0063] 3 Inlet area [0064]
4 Fan [0065] 5 Engine core [0066] 6 Compressor arrangement [0067] 7
Burner [0068] 8 Turbine arrangement [0069] 9 One-piece rotor area
[0070] 10 Annular base body [0071] 11 Blade element [0072] 12
Transition area [0073] 13 Surface of the base body [0074] 14
Rolling tool [0075] 15 Tool carrier [0076] 16 Carrier spindle
[0077] 17, 18 Pliers-type body [0078] 19 Rotating bearing [0079] 20
Driving unit [0080] 21, 22 Rolling area [0081] 23 Piston element
[0082] 24 Cylinder element [0083] 25 End of pliers-type body 17
[0084] 26 End of pliers-type body 18 [0085] 27 Rotary axis [0086]
28, 29 Piston element [0087] 30, 31 Spring-action device [0088] 32
Resetting device [0089] 33, 34 Ball element [0090] 35, 36 Holding
area [0091] 37, 38 Adapter element [0092] 39 Axis
* * * * *