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

燃气涡轮发动机的维护、维修和大修历来需要劳动密集型的人工视觉和尺寸检查来评估部件状况，并结合资本设备密集型的维修过程。随着发动机制造商将3D建模纳入设计过程，并将5轴加工纳入原始生产，压气机、风扇和涡轮叶片的几何形状变得极其复杂。这些关键旋转部件的检查、维护和维修需要高度的测量精度，以及评估材料质量的经验。前缘和后缘的尺寸评估，以及整体材料状况仍然主要是一个人工过程。非接触式三维检测系统现已广泛应用。然而，将视觉系统与智能控制系统和机械修复方法相结合是一项相对新兴的技术。在验证民用飞机上使用的概念和过程时，需要确定性和安全性因素，这使集成多个高精度电子和机械系统的复杂性更加复杂。

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.