U.S. patent number 3,590,454 [Application Number 04/803,901] was granted by the patent office on 1971-07-06 for turbine assembly fabrication.
Invention is credited to Edward A. Brass.
United States Patent |
3,590,454 |
Brass |
July 6, 1971 |
TURBINE ASSEMBLY FABRICATION
Abstract
A small turbine for a jet engine is disclosed in which each
bucket or blade is carried on a metal block which has a base
portion conforming to a gear tooth shape. Slots in the hub of the
turbine which receives the blade portion are cut on a gear cutting
machine, this machine being indexed in a highly precisional manner.
When the tooth-shaped portions of the blocks are assembled in the
hub slots, the assembly is placed in an electron beam welder and
the joints between the blocks and the hub, also between the
abutting blocks are welded to form an integral structure.
Inventors: |
Brass; Edward A. (Tustin,
CA) |
Assignee: |
|
Family
ID: |
25187729 |
Appl.
No.: |
04/803,901 |
Filed: |
March 3, 1969 |
Current U.S.
Class: |
29/889.21;
416/219R; 416/244R; 416/213R; 416/244A |
Current CPC
Class: |
B23P
15/006 (20130101); Y10T 29/49321 (20150115) |
Current International
Class: |
B23P
15/00 (20060101); B21k 003/04 (); B23p 015/02 ();
B23p 015/04 () |
Field of
Search: |
;29/156.8T,156.8B,156.8P,156.8H,156.8CF,156.8R ;416/213,219,223
;29/156.8B |
Foreign Patent Documents
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4,603 |
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Aug 1905 |
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GB |
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702,390 |
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Jan 1954 |
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GB |
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730,638 |
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May 1955 |
|
GB |
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752,921 |
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May 1953 |
|
DT |
|
Primary Examiner: Moon; Charlie T.
Assistant Examiner: Rooney; Donald P.
Claims
I claim:
1. In the art of fabricating a turbine wheel, the step of cutting
equidistantly spaced slots about the hub of the wheel, said slots
being cut to gear tooth configuration by a precisional gear cutting
machine, the further step of cutting blocks of metal having a lower
portion of the same form as a gear tooth of precisely the same
shape and size as said slots, and upper portion formed as a blade
of the turbine, the further step of inserting the lower portion of
the respective blocks in the slots so that the sides of the block
abut one another and securing the abutting surfaces of the blocks
and the abutting surfaces of the hub and the lower portions of the
block together to complete the fabrication of the turbine
wheel.
2. The method of fabricating a turbine wheel according to claim 1
and in which the securing step is accomplished by the use of
electron beam welding.
Description
BACKGROUND OF THE INVENTION
The present invention relates to turbine wheels, used in connection
with jet engines and more especially those of small size. A turbine
wheel is mounted on the compressor shaft and gas flows at high
velocity from the combustion chamber into a set of stationary
blades that form the entrance to the turbine wheel. These
stationary blades act as nozzles which serve further to accelerate
the gases. To the rear of the stationary set of blades a set of
rotating blades constituting a turbine wheel is presented to the
gases as they leave the stationary nozzles. These blades are so
designed so as to provide passageways which offer the minimum
resistance to the moving gases and thus cause e turbine to rotate
at a fast speed in order to turn e compressor. Since the latter
provides air under pressure to the combustion chamber of the jet
engine, it is essential in the interest of obtaining constant speed
and continuous driving force at the jet that the gas passageways in
the turbine be kept to a close tolerance depending on the shape of
the blades and their size. Otherwise, irregularities in the turning
effort at the compressor may occur and be reflected in the
delivered thrust.
In the case of the compressors and their corresponding large
turbines, greater tolerances as to size and shape of the space
between blades are normal because any variation is proportionally
less on account of the large amounts of gas being handled. It is
sufficient to form the slots in the hub by a broaching machine,
each slot having sides which taper inwardly and are grooved, so
that the arrangement sometimes is referred to as a "Christmas Tree"
shape. These grooves slidably receive protuberances on a block
which carries the blade. An appropriately positioned pin is driven
through the block to keep the blade from sliding out of position.
The resulting distance between blades is obviously not to a close
tolerance and would be completely unacceptable for turbines 2
inches to 4 inches outside diameter which handle very much less
gas.
In the case of small turbines with their diminutive gas
passageways, tolerances of any appreciable amount simply cannot be
allowed, but instead, they demand absolute accuracy of dimension
and shape which is most difficult to obtain.
In an attempt to obtain this accuracy of position and shape, it has
been proposed to cut the entire wheel including the blades out of
solid block material. But is procedure is expensive because the
cutting tool must be carefully controlled, by computer or tape, in
view of the intricate design of the blades.
In intermediate sizes, the turbine assemblies are sometimes cast in
one piece, i.e., the blades are integral with the hub but quality
is sacrificed in that the blading tolerances i.e., the blading
profiles and interblade spacings, are higher than in the separate
blade design. Integral turbine assemblies have also been fabricated
by the well-known EDM (Electrical Discharge Machining) method. This
method cuts the metal by a sparking or sputtering effect, using
extremely high voltage. However, it has been found that the
sputtering tends to create crack-propogating surfaces and also
leaves these surfaces quite rough which would obviously reduce the
streamline effect. Moreover, the sputtering electrode changes its
shape during operation which further adds to the irregularity of
the cut. If this method were used for the small size turbines,
i.e., of the order of 2 to 4 inches in diameter, it is impossible
to obtain the extremely close tolerance profiles are necessary.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved and practical
method of making small turbine wheels for jet engines.
Another object is provide a turbine wheel, particularly of small
size and in which the blades or buckets are tightly secured to the
periphery of the wheel.
Still another object is provide a small turbine in which the blades
are of complicated design and ether with the interblade spacing
must conform to extremely close tolerance.
A further object is to provide a relatively small turbine of the
kind mentioned and in which the manufacturing costs are relatively
low, notwithstanding the high precisional requirements.
These objects are obtained, in brief, by cutting slots of a gear
tooth shape in a hub by a precise gear cutting and indexing
machine, and providing a gear shape tooth on the base of the blade.
Thereafter, the base portion is fitted into the slot of the wheel
and the entire assembly is then welded by an electron beam, i.e.,
cathode-ray effect, to form an integral unit.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 represents a plan view of the improved turbine wheel.
FIG. 2 is a fragmentary end view of the hub portion of the wheel
and showing the gear tooth slots, ready to receive the blade
blocks.
FIG. 3 illustrates a partial end view of the turbine shown in FIG.
1 but with the blades broken away.
FIG. 4 is a perspective view, on a larger scale than in FIGS. 1 and
3, of a blade block.
FIG. 5 shows by way of diagram, a typical apparatus which may be
employed for making some of the welds in securing the blades to the
hub of the turbine wheel.
FIG. 6 illustrates, also by diagram, similar apparatus for making
the remaining welds on the wheel to complete the entire turbine
unit.
Referring more particularly to FIGS. 1 and 3, reference character 1
generally designates a relatively small turbine wheel having
centrally positioned vane or bucket portion 2. There is a pair of
outwardly directed sleeve portions 3 which are provided at their
inner ends with flange 4 for securement to a flange 5 of the hub
portion 6, (FIG. 2), as by welding. The sleeves 3 are provided with
flanges 7 at their outer ends. An axial bore 8 passes through the
turbine wheel for mounting the latter on a compressor shaft (not
shown) of a jet engine.
The turbine has a number of blades buckets 9 of which an outline of
each is shown in FIG. 1, and these blades are equally spaced about
the hub portion 6. An enlarged perspective view of the blade is
shown in FIG. 4. The blade is supporting number is cut to shape,
preferably from a solid block of metal by any appropriate machine
such as a milling or shaping machine in any suitable well-known
manner. The blade is of the well-known convolute shape having a
predetermined depth as indicated 10. The blades when assembled on
the turbine wheel are adapted to receive gases delivered by the
stationary ring of nozzles (not shown) to provide a strong and
continuous rotary effort on the compressor shaft. This shaft
carries a compressor (not shown) which provides air under high
pressure to a combustion chamber and the latter furnishes the gases
which rotate the turbine and produces a jetlike stream of gas for
propulsion purposes. The sides 11 of the block are parallel to one
another and extend obliquely, as seen in FIG. 1 and in the
particular case shown at about 45.degree. with respect to the front
and rear faces of the block in order to accommodate the angular
setting of the blade. These sides are of substantial thickness and
from the lower portions thereof there extends downwardly a
toothlike projection 12 (FIG. 4), similarly to the shape of a gear
tooth and is of precisely the same shape and size as the gear tooth
recesses are formed in the hub of the wheel as will be explained
hereinafter. As seen in FIG. 4, the toothlike projection 12 is not
centrally located with respect to the side portions 11 but slightly
to the left of the centerline between these two sides. Thus, there
is a fairly wide flat surface 13 between the right-hand side of the
root of the tooth 12 and the right-hand sidewall. The left-hand
side of the tooth terminates in a narrow curvilinear portion 14.
The purpose of these particular shapes at the root of the toothlike
extension or base will be made clear when the blocks are arranged
within recesses cut into the hub as will be explained
hereinafter.
As shown in FIG. 2, the hub 6 is placed on a gear cutting machine,
which, as is well known in the art, can be furnished with a high
precisional cutting tool and indexing device. Slots 5 (FIG. 2) are
cut into the hub in an oblique direction corresponding to the angle
of the sides 11 of the blocks these slots are shaped to conform
precisely to the shape of the tooth 12. The slots are equidistantly
spaced about the hub of the wheel, the number of which will depend
on the number of blades that are to be employed around the
periphery of the turbine. In view of the precisional manner in
which a gear cutting machine operates, including its indexing
feature, the slots 15 can be cut to an extremely close tolerance
both as to shape and spacing, similar to a high precisional gear.
Assuming that the blocks carrying the blades are similarly cut
accurately to size, the insertion of the tooth 12 in its
corresponding slot of the wheel will cause the sides of the block
closely to abut the adjacent block around the wheel. This close
abutting effect as between the blocks is indicated by the diagonal
lines 16 in FIG. 1. It will be noted that the abutting line between
the right-hand side 11 (FIG. 4) of the block is slightly to the
right of the centerline of the toothlike recess 10 over which it
extends on account of the wider area found at the surface 13 than
at the surface 14. It will be noted that due to the shape of the
toothlike extension 12 and the parallel sides 11 of the block, the
latter can either be slid into position from the side of the hub or
can actually be pushed downwardly toward the circumference of the
hub in order to assemble the blades in position. If desired, the
sides 11 can be given a slight "tow" inwardly to assure a still
tighter fit between blocks.
The next step is to join the various parts into an integral unit. I
have discovered and in accordance with another aspect of my
invention that instead of employing ordinary forms of welding, such
as the electrical discharge machine method, the design of having
the various blocks abut one another closely about the periphery of
the wheel and held within toothlike recesses in the hub lends
itself peculiarly well to the electron beam welding method which
will now be described. In FIG. 5, there is shown a typical machine
of this type and includes a large rectangular compartment 17
hermetically sealed, and evacuated to a very high degree. The lower
part or bottom of the compartment has a sealed opening for
receiving a shaft 18 connected to motor (not shown). This shaft
extends into the compartment and carries a circular table 19 which
has a fairly deep and wide slot running transversely over the face
of the table. On top of the table there is a circular plate 20 of
metal provided with a tongue which is adapted to slide within the
groove 21 formed in the table. The plate 20 carries a smaller plate
22 having a tongue 23 which is adapted to slide in a groove formed
at the top of the plate 20. The plate 22 is provided with a pair of
heavy thick uprights 24 of metal secured in any suitable manner to
the plate 22 and forming a support at two diametral positions along
the lower side surface of the wheel 1 so as to permit one of the
sleeve extensions 3 to extend downwardly between the two uprights.
The wheel may be secured to the upper surface of the uprights 24 in
any suitable well known manner. There are several mechanical
controls in the form of connecting rods, gear trans, gear-rack
mechanism and etc., which can move the plate 22 to any desired
distance and in any direction toward and away from the reader along
the slot 23, also to cause the plate 20 to move in a direction at
right angles to the movement of the plate 22 and along the slot 21.
These controls, also control of the direction of rotation of the
table 19 through its motor (not shown) can be exercised with
precision in any suitable and well-known manner from positions
exterior of the compartment. Thus, the turbine wheel positioned on
the uprights 24 can be moved universally in any horizontal
direction due the movement of the plates 22, 20 and the rotary
plate 19, but not in the vertical direction. The top portion or
upper cover of the compartment 17 has a sealed opening for
receiving a powerful cathode-ray gun 25 with suitable electrical
conductors diagrammatically indicated at 26 for the purpose of
producing intense cathode rays 27 which will impinge on the various
joints formed between the blade blocks and the hub of the wheel.
These conductors pass into control unit 27' supplied with
electrical energy from a source 28. The control apparatus 27'
houses the control panel including the various electromagnets,
switches, safety devices rheostats, etc., which are connected to
the various mechanical actuating devices (not shown) for the plates
22 and 20, also for rotating plate 19. That the control of these
elements rests in the control unit 27' is diagrammatically
indicated by the leader lines 29. All of these devices are well
known in the art, also the manner in which they control the
operating parts within the compartment 26 for moving the turbine
wheel very slowly in any direction in the horizontal plane. There
is shown a diffusion pump 30 and a mechanical pump 31 for providing
the high degree of vacuum necessary within the compartment when
using the cathode-ray gun 25. This apparatus needs no further
explanation as it is also well known in the art for providing high
vacuum. It is apparent that with careful manipulation of high
control apparatus 27', the various plates 22, 20 and 19 can be
moved in diminutive amounts along any and all of the side joints
between the blocks adjacent one another and also between each block
the abutting surface of each block and the abutting surface of the
wheel hub. This side welding effect is shown by the short cross or
transverse lines (indicated as stitches) in FIG. 3. After one side
of the wheel has been welded, the other side is then exposed to the
cathode rays so that the weld can be formed along both sides of the
wheel. This weld penetrates the joints to any suitable depth may be
desired depending upon the type of welding duration, and also the
intensity of the cathode rays 27.
In order to weld the circumferential joint areas of the wheel, a
mechanical setup such as shown in FIG. 6 may be employed. In is
figure, like pieces of apparatus similar to those shown in FIG. 5
have been given the same reference characters. The plate 22 and the
uprights 24 are dispensed with so that there is used at this time
the rotary table 19 and the traversing plate 20. The latter is
provided with a pair of uprights 32 terminating in the lower part
of a bearing which fits around the under surface of the sleeves 3
of the wheel. The bearing or journal is completed by a semicircular
member 33 which is provided with extensions 34 for bolting to
similar extensions on the lower part of the bearing. The bearing is
such as to permit the sleeve portions 3 to rotate freely and yet be
held rigidly in position above the plate 20. A shaft 35 extends
through the wheel and at its reduced end carries a gear 36 which
meshes with a smaller gear 37. The latter is supported on a shaft
37 which also carries a large gear 38. Gear 38 meshes with a small
gear 39 mounted the shaft of motor 40. Thus, as the motor is
energized from the control panel in any suitable well-known manner,
the array of gears provides a considerable reduction in the speed
of the shaft 35. Control is also exercised of the transverse
movement of the plate 20 and the rotary movement of the table 19,
when necessary.
Thus, as in the case of the FIG. 5, the cathode rays 27, which are
stationary in space, can be caused to impinge on any part of the
circumferential area of the wheel by proper control at the panel
27' and can weld the peripheral portions of the abutting surfaces
between the blocks 1 as indicated by the "stitching marks" in FIG.
1. The depth of the weld can be readily determined or controlled by
the speed with which the surface being welded is moved past the
point of impingement of the cathode rays and also by the intensity
of the rays. The latter is a function of the voltage applied to the
gun. It is therefore evident that the abutting surfaces of the
parts, both down the sides of the wheel and also along the
periphery can be firmly welded to each other by the cathode rays so
the parts including the blades mounted on the blocks constitute an
integral structure. It has been found that cathode-ray welding,
particularly in the case of turbine wheels of small diameter,
leaves the surface quite smooth, notwithstanding the firmness of
the weld and there are no concavities from which cracks or other
imperfections of the surface can occur. It is further evident that
the welding process, both along the sides of the wheel and also
around the circumference can be done automatically at the control
apparatus 27' so that the turbine wheels are in finished form
immediately after the welding operation and conform precisely to
uniform dimensions and spacing between the blades. By cutting the
slots or grooves 15 in the hub on a precision indexing gear cutting
machine of any suitable and well-known type, the peripheral
position of the blades i.e. the spacing is absolutely assured
provided that there is a close fit between the tooth-shaped
extension 12 on each block and the similarly shaped slot or groove
in the wheel hub.
* * * * *