Patent Application
20200030864
The present disclosure relates generally to forging assemblies, and more specifically, to forging assemblies having capacitance sensors.
Precision forging is a metallurgical process similar to stamping that utilizes a ram to force heated metal preforms into the shape of a die imprint. The process is generally very rapid, for example, a forging event can take place in less than 0.2 seconds. Forged parts for gas turbine engines (e.g., forged airfoils) may need to maintain tight dimensional controls, for example, some parts or part areas may require tolerances of ±0.003 inches (±0.076 mm). Inaccuracy, or misalignment, of the forging dies can increase variability in the final part, which can lead to low yields. Sources of variability in the forging process are difficult to detect, as limited data streams exist for informing engineering actions to improve process controls. Additionally, installation of forging dies can be time consuming, as confirming proper die alignment can be difficult.
A forging assembly is disclosed herein. In accordance with various embodiments, the forging assembly may comprise a first die and a second die configured to translate toward the first die. A first sensor may be coupled to at least one of the first die or the second die. The first sensor may be configured to output a first signal correlating to a first distance between the first die and the second die.
In various embodiments, the first sensor may comprise a capacitive sensor. In various embodiments, a second sensor may be configured to output a second signal correlating to a second distance between the first die and the second die. The first distance may be measured in a first direction and the second distance may be measured in a second direction different from the first direction.
In various embodiments, a third sensor may be configured to output a third signal correlating to a third distance between the first die and the second die. The third distance may be measured in a third direction different from the first direction and the second direction.
In various embodiments, a data acquisition system may be operably coupled to the first sensor. A tangible, non-transitory memory may be configured to communicate with the data acquisition system. The tangible, non-transitory memory may have instructions stored thereon that, in response to execution by the data acquisition system, cause the data acquisition system to perform operations, comprising: receiving, by the data acquisition system, the first signal from the first sensor, and determining, by the data acquisition system, a location of the second die relative to the first die based on the first signal. In various embodiments, the instructions may cause the data acquisition system to perform operations further comprising at least one of: calculating, by the data acquisition system, a velocity of the second die; calculating, by the data acquisition system, an acceleration of the second die; determining, by the data acquisition system, an elastic deformation of the second die; or determining, by the data acquisition system, an elastic deformation of the first die.
In various embodiments, a field of view of the first sensor may be greater than or equal to the first distance as measured at a moment of contact between the second die and a workpiece located on the first die. In various embodiments, the first die may define at least one of a cavity or a protrusion. The first sensor may be located at least one of within the cavity or on the protrusion.
Also disclosed herein, in accordance with various embodiments, is a forging assembly comprising a first die and a second die configured to translate toward the first die. A first sensor may be coupled to at least one of the first die or the second die. The first sensor may be configured to output a first signal correlating to a first distance between the first die and the second die. A data acquisition system may be configured to receive the first signal.
In various embodiments, a tangible, non-transitory memory may be configured to communicate with the data acquisition system. The tangible, non-transitory memory may have instructions stored thereon that, in response to execution by the data acquisition system, cause the data acquisition system to perform operations, comprising: receiving, by the data acquisition system, the first signal from the first sensor, and determining, by the data acquisition system, a location of the second die relative to the first die based on the first signal.
In various embodiments, the instructions may cause the data acquisition system to perform operations further comprising at least one of: calculating, by the data acquisition system, a velocity of the second die; calculating, by the data acquisition system, an acceleration of the second die; determining, by the data acquisition system, an elastic deformation of the second die; or determining, by the data acquisition system, an elastic deformation of the first die.
In various embodiments, a forge press controller may be operably coupled to the data acquisition system and the second die. A tangible, non-transitory memory may be configured to communicate with the forge press controller. The tangible, non-transitory memory may have instructions stored thereon that, in response to execution by the forge press controller, cause the forge press controller to perform operations, comprising: receiving, by the forge press controller, a data output from the data acquisition system, and sending, by the forge press controller, a command signal configured to modify an operating parameter of the second die. In various embodiments, the operating parameter may comprise at least one of a velocity of the second die, an acceleration of the second die, a press power setting, or a position of the second die relative to the first die.
In various embodiments, a second sensor may be configured to output a second signal correlating to a second distance between the first die and the second die. The first distance may be measured in a first direction and the second distance may be measured in a second direction different from the first direction.
In various embodiments, a second sensor may be configured to output a second signal correlating to a second distance between the first die and the second die. The first distance may be measured in a first direction, and the second distance may be measured in the first direction. In various embodiments, the first sensor may comprise a capacitive sensor.
A method for analyzing performance of a forging assembly is also disclosed herein. In accordance with various embodiments, the method may comprise the step of coupling a sensor to at least one of a first die of the forging assembly or a second die of the forging assembly. The sensor may be configured to output a first signal correlating to a first distance between the first die and the second die. The method may further comprise the steps of disposing a workpiece on a first imprint surface of the first die, contacting the workpiece with a second imprint surface of the second die, and determining an operating parameter of the forging assembly based on the first signal.
In various embodiments, determining the operating parameter may comprise at least one of calculating a velocity of the second die, calculating an acceleration of the second die, calculating an elastic deformation of at least one of the first die or the second die, or determining a location of the second die relative to the first die.
In various embodiments, the method may further comprise comparing the operating parameter to a standard operating parameter. In various embodiments, the method may further comprise sending a command signal configured to modify the operating parameter of the forging assembly.
The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.
The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.
The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the exemplary embodiments of the disclosure, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not limitation. The steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented.
Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. Surface cross hatching lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.
Cross hatching lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials. Throughout the present disclosure, like reference numbers denote like elements. Accordingly, elements with like element numbering may be shown in the figures, but may not be necessarily be repeated herein for the sake of clarity.
Airfoils may be utilized in various sections of a gas turbine engine to direct, condition, and affect the flow of fluid (e.g., air and/or combustion gases) through the gas turbine engine. Current systems and methods for forming the airfoils may employ forging assemblies configured to shape the metal material of the airfoil between a pair of dies. Such dynamic systems and methods can impart variability in the shape of the airfoils. For example, elastic deformation, wear, and/or other movement of dies may alter the camber or other parameters of the airfoil geometry. Variability in the camber or in other airfoil dimensional parameters (e.g., leading edge angle, trailing edge angle, etc.) may lead to variations in the flow characteristics and flow capacity of the airfoil. Airfoil assemblies that do not meet stringent dimensional tolerance requirements may be discarded, which tends to increase material waste and cost.
Disclosed herein is a forging assembly having sensors configured to measure a distance between the two mating dies. The sensor may continuously measure die closure and alignment behavior in close proximity to an imprint surface of the die. The data output from the sensors may provide insight into the forging process, provide a baseline for understanding press variability, and/or inform decisions needed to determine final forging dimensions and/or improve part dimensional yields. The forging assembly may include a data acquisition system configured to track die closure behavior (distance vs. time) with high precision during a forging event. Forging assemblies as disclosed herein may be associated with reduced setup time, as compared to traditional forging assemblies, as the sensors can provide accurate and rapid die alignment data. Accordingly, forging assemblies having one or more die position sensor may enable the production of dimensionally accurate airfoils or other engine parts, while also reducing forge press setup time.
With reference to
With reference to
As will be discussed in further detail below, airfoil 100 may be fabricated by forging a metallic material 120, such as a metal and/or a metal alloy, into a preselected or desired shape. Metallic material 120 may include aluminum, aluminum alloy, titanium, titanium alloy, a nickel-based alloy or nickel-based super alloy, or any other suitable metal, metal alloy, or combination thereof.
With reference to
It will be noted that airfoils for gas turbine engines may be provided in the variety of sizes, shapes, and geometries. Accordingly, airfoil 100 of the present disclosure is not limited to the specific geometry, size, and shape shown in the figures. Further, while forging assembly 150 is described as being employed to form airfoils, it is further contemplated and understood that forging assemblies, as disclosed herein, may be employed to form components other than airfoils.
One or more sensors 160 may be coupled to die 152 and/or die 154. Sensors 160 are configured to output a signal corresponding to a distance between die 152 and die 154. In various embodiments, sensors 160 comprise capacitance sensors capable of measuring a distance between moving metallic objects (e.g., dies 152 and 154) based on change in capacitance. In various embodiments, each sensor 160 has a field of view that allows the sensor to detect die 154 (or die 152 for sensors coupled to die 154) at, and/or just prior to, a moment of contact between die 154 and workpiece 130. Stated differently, the field of view of each sensor 160 is greater than the distance between die 152 features and die 154 features at the moment of contact between impact surface 155 and workpiece 130. Stated yet another way, features of die 154 (e.g., protrusion 156) will be within the field of view of sensors 160 attached to die 152 at the moment of contact between impact surface 155 and workpiece 130, and features of die 152 (e.g., protrusion 157) will be within the field of view of sensors 160 attached to die 154 at the moment of contact between impact surface 155 and workpiece 130.
In various embodiments, sensors 160 may be affixed to die 152 and/or die 154 via a magnetic coupling. For example, sensors 160 may be affixed to magnets which are then magnetically coupled to dies 152 and 154. Magnetically coupling the sensors to the die may allow the sensors to be moved and positioned anywhere on die 152 and/or on die 154. Sensors 160 may also be attached to die 152 and/or die 154 via tape, adhesive, mechanical attachments, fasteners, or any other suitable attachment device.
In various embodiments, a first sensor 160a may be configured to detect a first distance D1 between die 152 and die 154. In various embodiments, first distance D1 may be measured in a first direction, for example, in a direction along the Y-axis of the provided XYZ axes. Stated differently, first sensor 160a may detect a positioning of die 154 relative to die 152 in a first plane (e.g., a plane parallel to the Y-axis).
In various embodiments, a second sensor 160b may be configured to detect a second distance D2 between die 152 and die 154. In various embodiments, second distance D2 may be measured in a second direction, for example, in a direction along the Z-axis (i.e., orthogonal to the first direction and the Y-axis). Stated differently, second sensor 160b may detect a positioning of die 154 relative to die 152 in a second plane (e.g., a plane parallel to the Z-axis and orthogonal to Y-axis).
In various embodiments, a third sensor 160c may be configured to detect a third distance D3, with momentary combined reference to
In various embodiments, die 154 may include one or more protrusions 156, and die 152 may define one or more cavities 158 configured to receive protrusions 156. In accordance with various embodiments, one or more sensors 160 may be located within cavities 158. In various embodiments, one or more sensors 160 may be attached to protrusions 156. In various embodiments, die 152 may include one or more protrusions 157, and die 154 may define one or more cavities 159 configured to receive protrusions 157 of die 152. One or more sensors 160 may be located on protrusions 157 of die 152 and/or in cavities 159 defined by die 154.
With reference to
Data acquisition system 180 may be in logical and/or operable and/or electronic communication with sensors 160. In this regard, data acquisition system 180 may receive data signals 162 output from sensors. Signals 162 may be sent to data acquisition system 180 as a voltage signal, a current signal, a digital signal, or any other suitable signal, whether filtered, conditioned, or otherwise preprocessed. Signals 162 may correlate to the distance between die 152 and die 154 due to voltage-to-distance calibration of the capacitance sensors 160. For example, first sensor 160a may output a first signal 162a correlating to first distance D1, as measured in the direction of the Y-axis, between die 152 and die 154. Second sensor 160b may output a second signal 162b correlating to second distance D2, as measured in the direction of the Z-axis, between die 152 and die 154. Third sensor 160c may output a third signal 162c correlating to third distance D3, as measured in the direction of the X-axis, between die 152 and die 154. In various embodiments, sensors 160 and data acquisition system 180 may be capable of measuring and recording at high frequencies (e.g., at frequencies greater than 1 kHz), thereby allowing data acquisition system 180 to capture data from very rapid forging events (e.g., 0.2 seconds or less). The frequency of data acquisition system 180 may be adapted to the duration of the forging event. In this regard, for slower forge processes (e.g., forge processes employing a hydraulic press), data acquisition system 180 may measure and record at frequencies less than 1 kHz, and for faster forge processes (e.g., forge processes employing hammers), data acquisition system 180 may measure and record at frequencies greater than 1 kHz.
Data acquisition system 180 may use the signals 162 received from sensors 160 to determine various operating parameters of dies 152 and 154. For example, data acquisition system 180 may use signals 162 to determine a location of die 154 relative to die 152, to calculate a velocity and/or acceleration of die 154, and/or to measure an elastic deformation of die 152 and die 154 upon impact with workpiece 130. Allowing data acquisition system 180 to monitor the kinetic press behaviors, such as the closing velocity and acceleration (i.e., distance vs. time), and the alignment of dies 152 and 154 may provide high precision insight during the forging process. Utilization of in-situ process monitoring data can provide a baseline for understanding press variability and inform decisions needed to reduce part variability and improve part dimensional yield.
With reference to
Forge press controller 190 may be in logical and/or operable and/or electronic communication with data acquisition system 180 and die 154. In this regard, forge press controller 190 may receive an operational data signal 194 output from data acquisition system 180 and may output a command signal 196 configured to change one or more operating parameters of die 154 based on the operational data signal 194. Signals 194 and 196 may be sent as a voltage signal, a current signal, a digital signal, or any other suitable signal, whether filtered, conditioned, or otherwise preprocessed. Operational data signals 194 may correlate to one or more operating parameters of the forge press actuating and/or controlling dies 152 and 154. Forge press controller 190 may be configured to compare the operational data signals 194 to a corresponding standard operating parameter. Forge press controller 190 may determine that one or more operating parameters (e.g. closing speed, die position, press power setting, etc.) for die 154 may need to be modified for future forgings based on the comparison. In this regard, command signal 196 may be configured to modify an operating parameter of die 154.
With reference to
In various embodiments, method 200 may further include comparing the operating parameter to a standard operating parameter (step 210). In various embodiments, method 200 may further include sending a command signal configured modify the operating parameter in a subsequent forging operation (step 212).
In various embodiments, step 208 may include calculating a velocity of the second die or calculating an acceleration of the second die. In various embodiments, step 208 may include determining a location of the second die relative to the first die. In various embodiments, step 208 may include calculating an elastic deformation of the first die or the second die.
With combined reference to
Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various FIGS. contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.
Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it may be within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element is intended to invoke 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
