This specification is based upon and claims the benefit of priority from UK Patent Application Number 1712479.3 filed on 3 Aug. 2017, the entire contents of which are incorporated herein by reference.
The present disclosure concerns a method of manufacture and/or a method of water jet cutting.
Gas turbine engines are typically employed to power aircraft. Typically a gas turbine engine will comprise an axial fan driven by an engine core. The engine core is generally made up of one or more turbines which drive respective compressors via coaxial shafts. The fan is usually driven off an additional lower pressure turbine in the engine core.
The fan includes a plurality of blades arranged around a hub. The blades may be metallic or composite blades. Composite blades generally include a body made from a carbon reinforced plastic matrix which may be reinforced in various ways. A metallic leading edge, and often a metallic trailing edge is provided on the body.
The metallic leading edge can be manufactured in a number of different ways, and in some examples the metallic leading edges need to be cut during the manufacturing process. This cutting can be done using water jet cutting. Water on its own is not sufficiently abrasive to cut the metal, so abrasive garnet particles are added to the water. However, the garnet can become embedded in the metal work contaminating the surface of the cut component. Garnet is chemically inert, so it is not readily removed using chemical processes and as such mechanical processes need to be employed to remove the embedded particles. Removal of the garnet particles from the surface of the component adds cost and time to the manufacturing process.
According to an aspect there is provided a method of manufacturing a part, the method comprising providing a component for cutting and directing a water jet at the component so as to cut the component. The water jet comprises water and abrasive particles having a nucleus made from a first substance and a second substance surrounding the nucleus. The first substance may be denser than the second substance. The second substance may be a liquid at atmospheric temperature and pressure. The first substance may be solid at atmospheric temperature and pressure. The second substance may be a frozen liquid, e.g. the second substance may be ice. Ice refers to frozen water. Frozen water consists essentially of H2O and any impurities. In alternative examples, the second substance may be an alternative frozen liquid.
The nucleus may comprise carbon. The nucleus may consist of or consist essentially of carbon or carbon fibre. The nucleus may comprise one or more carbon fibres or particles.
The nucleus may be defined by a single carbon fibre.
The nucleus may comprise acrylic. The acrylic nucleus may be 3D printed prior to being surrounded by the second substance.
The part may be a fan blade for a gas turbine engine, e.g. the component once cut may be a metal leading edge or trailing edge of a fan blade.
According to an aspect there is provided a method of water jet cutting a component, the method comprising providing a component for cutting and directing a water jet at the component so as to cut the component. The water jet comprises water and abrasive particles having a nucleus made from a first substance and a second substance surrounding the nucleus, the second substance being different to the first substance.
The method may comprise one or more features of the previous aspect.
According to an aspect there is provided a method of manufacturing a part, the method comprising providing a component for cutting and directing a water jet at the component so as to cut the component, the water jet comprising water and carbon particles.
The method may comprise one or more features of the previous aspect.
According to an aspect there is provided a method of water jet cutting comprising providing a component for cutting, and directing a water jet at the component so as to cut the component. The water jet comprises water and carbon particles.
The carbon particles may be surrounded in a substance that is liquid at atmospheric temperature and pressure. For example, the carbon particles may be surrounded by ice.
The method may comprise one or more features of the previous aspect.
The skilled person will appreciate that except where mutually exclusive, a feature described in relation to any one of the above aspects may be applied mutatis mutandis to any other aspect. Furthermore except where mutually exclusive any feature described herein may be applied to any aspect and/or combined with any other feature described herein.
Embodiments will now be described by way of example only, with reference to the Figures, in which:
With reference to
The gas turbine engine 10 works in the conventional manner so that air entering the intake 12 is accelerated by the fan 13 to produce two air flows: a first air flow into the intermediate pressure compressor 14 and a second air flow which passes through a bypass duct 22 to provide propulsive thrust. The intermediate pressure compressor 14 compresses the air flow directed into it before delivering that air to the high pressure compressor 15 where further compression takes place.
The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion equipment 16 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 17, 18, 19 before being exhausted through the nozzle 20 to provide additional propulsive thrust. The high 17, intermediate 18 and low 19 pressure turbines drive respectively the high pressure compressor 15, intermediate pressure compressor 14 and fan 13, each by suitable interconnecting shaft.
Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. By way of example such engines may have an alternative number of interconnecting shafts (e.g. two) and/or an alternative number of compressors and/or turbines. Further the engine may comprise a gearbox provided in the drive train from a turbine to a compressor and/or fan.
The fan 13 includes a plurality of fan blades 24 arranged around a hub. In the present example, the fan blades are composite fan blades and include a metallic leading edge 25. The metallic leading edge is made from metal and is at least partially cut to size using water jet cutting.
The method of water jet cutting will now be described in more detail. Referring to
Referring to
The carbon fibre is defined by short sharp lengths of carbon. These can be produced with a high aspect ratio. The carbon fibres can be bought off the shelf or may be manufactured from carbon rod stock. To manufacture the carbon fibres, conventional methods can be used such as a using a slotted cutting wheel or shearing jaws.
Referring now to
To cut a component, solid particles are supplied to the hopper 40, either continuously or in batches. High pressure water is supplied through the inlets 42A, 42B. This water then flows to the water outlet 44. Simultaneously, particles are released from the hopper into the water in the outlet. The orifice 48 then funnels the water and particles to have the desired jet properties for a given application. For example, the orifice can be dimensioned for high speed cutting, high precision edge or super fine precision edge.
In the present example, the particles 34 having a carbon fibre nucleus and surrounding substance are made prior to being delivered to the hopper 40. The abrasive particles may be formed in a number of different ways, for example using sublimation, an atomiser or particles may be swirled in a super saturated liquid prior to be placed in a long drop condensing chamber.
Referring to
In alternative embodiments, the ice and carbon fibre particles may be made in situ within the cutting equipment. For example, referring to
In the described example, the particles are less likely to embed in the surface of a cut component compared to the garnet particles of the prior art because of the ice surrounding the nucleus. Further, carbon fibre can be more easily removed from the surface of a component than garnet.
Provision of a nuclei, e.g. carbon fibre nuclei, means that the particles have increased momentum compared to particles made only from ice, which means that the cutting performance can be improved compared to water jet cutting using only ice particles.
As discussed previously, carbon can be more easily removed from a surface than garnet. As such, advantages over the conventional garnet water jet cutting process can be achieved by using carbon as the abrasive particle, i.e. carbon not surrounded by ice. To utilise carbon only particles a similar method to that described and illustrated in
In exemplary embodiments, the hopper may comprise a belt e.g. a multi-feed option. In examples of the described methods, the cartridge 40 may be oscillated at high frequency to improve distribution of the particles into the water stream. Cartridges are ideally disassembled and cleaned prior to replacement of media for repeated use.
In alternative examples, the nuclei may not be made from carbon fibre. For example the nuclei may be made from an acrylic. The acrylic may be produced in a colloidal dispersion using high-shear mixing or by 3D printing to form particles having a desired shape, for example angular particles with sharp edges. Selecting the desired shape of the particles can result in more favourable abrasive particle shapes (e.g. the shape of the acrylic nuclei and ice formed around the nuclei) for improved cutting.
In further alternative examples the nuclei may be formed from a crystalline solid, for example uric acid crystals or crystals of other organic acids e.g. diprotic acids, citric acid, malic acid, tartaric acid, or folic acid. In other examples the crystals may comprise calcium, for example calcium oxalate. The crystals may be formed from hydroxyapatite. The crystals may be formed from urea or derivatives thereof, for example heterocyclic urea, or hydroxycarbamide. In many examples it is desirable for the crystals to be formed from a heterocyclic compound. In alternative examples, the crystalline solids may comprise metal ions. For example, calcium, magnesium, sodium, lithium, or potassium may be added to the composition of the crystalline solids.
It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.
Number | Date | Country | Kind |
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1712479.3 | Aug 2017 | GB | national |