Patent Application
20070241215
This invention relates generally to fabricating components, and more specifically to supplying coolant to components during fabrication thereof.
For at least some known machining processes, for example multi-axis milling or grinding processes, components may be coupled to a fixture that is mounted on a table that rotates and translates about at least one axis to facilitate machining various surfaces of the component. To avoid heat damage to the component, cooling fluid may be discharged toward the machining zone to facilitate cooling the component during machining. Stationary nozzles are sometimes used to direct cooling fluid toward the machining zone, however, depending on the orientation of the component, it may be difficult to provide adequate cooling fluid to the machining zone. For example, depending on the component, a path of coolant discharged from such stationary nozzles may become obstructed as the component is reoriented.
Accordingly, to ensure an adequate supply of cooling fluid is available, at least some known nozzles are coupled to the fixture such that the nozzle moves with the fixture and is maintained in the same alignment with respect to the machining zone during movement of the fixture. For example, cylindrical tubes are sometimes coupled to the fixture and bent into position to direct cooling fluid toward the machining zone. However, nozzles coupled to the fixture may inadvertently become damaged or misaligned as the component is coupled to the fixture, and/or during maintenance of the fixture. Moreover, some known nozzles are coupled to the fixture using fittings that may loosen during movement of the fixture, thus enabling the nozzles to become misaligned. Damage to, and/or misalignment of, such nozzles may cause insufficient cooling fluid to be supplied to the machining zone, which may damage the component.
In one aspect, a method is provided for fabricating a nozzle. The method includes providing at least two plates. At least one of the at least two plates includes a first opening. Each plate includes at least one mating surface. The method also includes stacking the at least two plates together such that a mating surface of a first of the at least two plates is substantially flush against a mating surface of a second of the at least two plates, and such that a fluid passage is at least partially defined by the at least two plates. The method also includes orienting the at least two plates relative to each other such that the opening within at least one of the at least two plates at least partially defines an outlet for discharging fluid from the fluid passage.
In another aspect, a nozzle includes at least two plates each having at least one mating surface. The at least two plates are stacked together such that a mating surface of a first of the at least two plates is substantially flush against a mating surface of a second of the at least two plates and such that a fluid passage is at least partially defined by the at least two plates. At least one of the at least two plates includes an opening that at least partially defines an outlet for discharging fluid from the fluid passage.
In yet another aspect, a nozzle assembly includes a base including a first fluid passage and a first opening. The first fluid passage extends from a first end that is generally adjacent the first opening to a second end. The first fluid passage is configured to couple in flow communication with a source of fluid. The nozzle assembly also includes a nozzle including at least two plates each having at least one mating surface. The at least two plates are stacked together at least partially within the first opening such that a mating surface of a first of the at least two plates is substantially flush against a mating surface of a second of the at least two plates and such that a second fluid passage is at least partially defined by the at least two plates. The second fluid passage is in flow communication with the first end of the first fluid passage for receiving fluid therefrom. At least one of the at least two plates includes a second opening that is in flow communication with the second fluid passage and that at least partially defines an outlet for discharging fluid from the second fluid passage.
As used herein the terms “machining,” “machine,” and “machined” may include any process used for shaping a component. For example, processes used for shaping a component may include, but are not limited to including, turning, planing, milling, grinding, finishing, polishing, and/or cutting. In addition, and for example, shaping processes may include, but are not limited to including, processes performed by a machine, a machine tool, and/or a human being. The above examples are intended as exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the terms “machining,” “machine,” and “machined”. In addition, as used herein the term “component” may include any object that has been or may be machined.
Fixture 30 generally includes a base 32, at least one clamping member 34 coupled to base 32, and at least one nozzle assembly 36 coupled to base 32. In one embodiment, base 32 is fixedly secured to a table 31 that rotates and translates about one or more axes (not shown) to facilitate machining various surfaces of engine blade 10. For example, when base 32 is fixedly coupled to table 31 and engine blade 10 is fixedly coupled to fixture 30 (as described below in more detail), base 32, and engine blade 10, can be moved about one or more axes to allow a machining tool (not shown) access to various surfaces of engine blade 10 for machining thereof.
Engine blade 10 is fixedly coupled to fixture 30 using clamping members 34. Although only two clamping members 34 are illustrated, fixture 30 may include only one, or any number of, clamping members 34. Clamping members 34 may be movable with respect to base 32, for example using electrical, hydraulic, and/or pneumatic power, for fixedly coupling blade 10 to fixture 30. Moreover, rather than being movable, one or more of clamping members 34 may be fixed with respect to base 32. Claming members 34, whether moveable or fixed, include surfaces (e.g., a surface 38) sized and shaped to engage engine blade 10 and secure engine blade 10 to fixture 30. Of course, it should be appreciated that the specific size, shape, and/or configuration of clamping members 34 illustrated herein is exemplary only. Accordingly, the specific size, shape, and/or configuration of clamping members 34 may be selected to accommodate other components than engine blade 10, or may be selected to clamp blade 10 in other configurations than described and/or illustrated herein.
Nozzle assemblies 36 are generally positioned to discharge a cooling fluid (not shown) toward engine blade 10 during machining thereof. Cooling engine blade 10 during machining facilitates protecting blade 10 from damage that may occur as heat is generated as a result of machining. Over time, continued exposure to heat may cause thermal stresses, cracking, burning, and/or micro-structural damage to blade 10. Although only two nozzle assemblies 36 are illustrated, fixture 30 may include only one or any number of nozzle assemblies 36. Fixture 30 may include a coolant supply tube 40 that is coupled in flow communication with a source of cooling fluid (not shown). In some embodiments, nozzle assemblies 36 receive cooling fluid from supply tube 40 via passages (not shown) defined within base 32 and another portion 33 of fixture 30. In some embodiments, nozzle assemblies 36 receive cooling fluid channeled from supply tube 40. Moreover, in some embodiments, nozzle assemblies 36 are each independently connected to the source of cooling fluid for receiving cooling fluid therefrom.
As shown in
As shown in
When plates 54, 56, 58, 60, and 62 are stacked and received within base opening 46, fluid passage 70 is in flow communication with fluid passage end 50 for receiving cooling fluid therefrom. At least one of plates 54, 56, 58, 60, and 62 includes an opening (e.g., opening 96 described below) that is in flow communication with fluid passageway 70. Plates 54, 56, 58, 60, and/or 62 are orientated relative to each other such that the opening at least partially defines an outlet 94 for discharging cooling fluid from fluid passage 70 towards blade 10. As shown in
A size and/or shape of fluid passage 70 is pre-selected to facilitate providing a desired flowrate and/or a desired flow pattern of the cooling fluid within fluid passage 70. As can be appreciated by one skilled in the art, the size and/or shape of each of openings 82, 84, 86, and 88, as well as the arrangement of the stack of plates 54, 56, 58, 60, and 62 is variably selected to provide a desired size and/or shape of fluid passage 70. Although fluid passage 70 may include any general shape, in some embodiments, fluid passage 70 includes a generally circular, oval, triangular, and/or quadrilateral cross section.
Similarly, a size and/or shape of outlet 94 is variably selected such that cooling fluid discharged from outlet 94 has a pre-selected flowrate and/or a pre-selected cross-sectional discharge pattern, for example, to facilitate providing a desired flow of cooling fluid to blade 10. As can be appreciated by one skilled in the art, the size and/or shape of opening 96 (and/or any other openings defining outlet 94), as well as an arrangement of the stack of plates 54, 56, 58, 60, and 62 can be pre-selected to provide the desired size and/or shape of outlet 94. Although outlet 94 may include any general shape, in some embodiments, outlet 94 includes a generally circular, oval, triangular, and/or quadrilateral cross section.
In operation, and for example, cooling fluid is received by supply tube 40 and flows through the passages within base 32 and portion 33 of fixture 30, fluid passage 48 of nozzle assembly base 42, and into fluid passage 70 of nozzle 44. Cooling fluid is then discharged through outlet 94 and thereby delivered to engine blade 10 to cool engine blade 10. Because nozzle assembly base 42 is generally rigid and nozzle 44 is fixedly retained within opening 46 of base 42, nozzle 44 may be less likely to be damaged or misaligned during loading of blade 10 onto fixture 30 and/or during maintenance of fixture 30. Nozzle 44 may also be less likely to vibrate loose during movement of fixture 30 because base 42 is fixedly coupled to fixture 30 and nozzle 44 is fixedly retained within opening 46. Moreover, even if nozzle 44 is damaged, nozzle 44 can be replaced with an undamaged nozzle by replacing plates 54, 56, 58, 60, and/or 62 with undamaged plates. Accordingly, nozzle assembly 36 may facilitate easier replacement of nozzle 44 without realignment thereof, possibly leading to shorter maintenance times. Moreover, if different nozzles are desired, for example due to machining of a different component, different machining processes of the same component, and/or machining different areas of the same component, nozzle assembly 36 may facilitate shorter cycle times between components and/or processes.
Although the nozzles, assemblies, and methods described and/or illustrated herein are described and/or illustrated with respect to gas turbine engine components, and more specifically a rotor blade for a gas turbine engine, practice of the nozzles, assemblies, and methods described and/or illustrated herein is not limited to engine blades, nor gas turbine engine components generally. Rather, the nozzles, assemblies, and methods described and/or illustrated herein are applicable to any component and/or any machining process.
Exemplary embodiments of methods, nozzles, and assemblies are described and/or illustrated herein in detail. The methods, nozzles, and assemblies are not limited to the specific embodiments described herein, but rather, components of each nozzle and components of each assembly, as well as steps of each method, may be utilized independently and separately from other components and steps described herein. Each component, and each method step, can also be used in combination with other components and/or method steps.
When introducing elements/components/etc. of the methods, nozzles, and assemblies described and/or illustrated herein, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the element(s)/component(s)/etc. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
