Technology Expansion of Adaptive Machining for Gas Turbine Aero-Engine Applications (Re-submission)

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Maintenance, repair and overhaul of gas turbine engines has historically required labour intensive manual visual and dimensional inspection to assess component conditions, combined with capital equipment intensive repair processes. Compressor, fan and turbine blade geometry has become extremely complex as engine manufacturers have incorporated 3D modelling into the design process and 5-axis machining into original production. The inspection, maintenance and repair of these critical rotating parts involve high degrees of measurement precision, and experience in assessing material quality. Dimensional assessment of leading and trailing edge, and overall material condition is still primarily a manual process. Non-contact three dimensional inspection systems are now widely available. However, the integration vision systems with intelligent control systems and mechanical repair methods is a relatively emerging technology. Compounding the complexity of integrating multiple highly precise electronic and mechanical systems is the factor of certainty and safety required in proving concepts and processes for use in civilian aircraft. StandardAero partnered with Red River College to obtain an automated system which was designed to inspect and mechanically dress blades of a particular configuration to restore for service. The main objective is to identify and validate a method for adapting to additional part configurations through in depth analysis of the integrated systems, development of necessary modifications and subsequent experimentation. The learnings from the project will allow StandardAero to expand their advanced manufacturing capabilities. Implementation of the results from this applied research will directly impact the production efficiency for blade inspection and repair. With the growing demand for the aerospace sector to adopt advanced manufacturing practices, an applied research project to implement and develop automated gas turbine blade inspection and repair will definitively contribute to Canadian companies' ability to remain competitive within the aerospace industry.