Abstract: A method and system estimates manufacturing costs for conventional and advanced materials and processes based on process-oriented approach. A computer system input display for selecting one or more designs and one or more design parameters. Cost models are based upon process-oriented manufacturing cost estimates for a plurality of designs utilizing materials and manufacturing processes. Software is programmed to receive selected designs and selected design parameters from the input display and pass the selected designs and design parameters to the cost models. An output display shows the manufacturing costs estimated by the cost models for the selected designs and design parameters. A manufacturing process flow simulation model highlights and quantifies the magnitude of the manufacturing process cost drivers. An architecture including a relational database is also disclosed, and input and editing modules can be utilized to modify the cost model equations or to provide input from other software applications.

Abstract: A method and system estimates manufacturing costs for conventional and advanced materials and processes based on a process-oriented approach. A computer system comprises an input display for selecting one or more designs and one or more design parameters. Cost models are based upon process-oriented manufacturing cost estimates for a plurality of designs utilizing materials and manufacturing of processes. Software is programmed to receive selected designs and selected design parameters from the input display and pass the selected designs and design parameters to the cost models. An output display shows the manufacturing costs estimated by the cost models for the selected designs and design parameters. A manufacturing process flow simulation model highlights and quantifies the magnitude of the manufacturing process cost drivers.

Abstract: A method and passage system is applicable to hollow structures, such as hollow rib core fan blades, for removing alpha case and contamination, for improving surface texture, and for smoothing diffusion bonded joints to reduce notches and flaws, after fabrication. The passage system allows for venting and full cavity access to permit cleaning of the interior of the hollow structure. The method of cleaning the interior of a hollow structure may comprise applying an etchant to strip the topical layer from the inside of a hollow mechanical structure, such as a hollow core airfoil; or may comprise pumping an abrasive flow through the hollow cavities of the structure.

Abstract: A method and passage system is applicable to hollow structures, such as hollow rib core fan blades, for removing alpha case and contamination, for improving surface texture, and for smoothing diffusion bonded joints to reduce notches and flaws, after fabrication. The passage system allows for venting and full cavity access to permit cleaning of the interior of the hollow structure. The method of cleaning the interior of a hollow structure may comprise applying an etchant to strip the topical layer from the inside of a hollow mechanical structure, such as a hollow core airfoil; or may comprise pumping an abrasive flow through the hollow cavities of the structure.

Abstract: A sheet metal panel comprising a bent region is disclosed. The region defines a first arc of intersection with a first plane and a second arc of intersection with a second plane. The second arc has a radius of less than twice the thickness of the panel.

Abstract: A method of fabricating sheet metal panels and the article produced thereby. According to one form, the method of fabrication includes the steps of providing a panel of sheet metal, perforating the panel to provide a plurality of holes, forming the panel into a preselected curve about a longitudinal centerline, forming the leading edge portion of the panel into a front flange, forming a shoulder in the panel centered on the holes and extending perpendicularly from a surface thereof, bending an outer portion of the shoulder into a lip, and bonding the portions of the panel comprising the shoulder and lip.

Abstract: A method of fabricating sheet metal panels and the article produced thereby. According to one form, the method of fabrication includes the steps of providing a panel of sheet metal, perforating the panel to provide a plurality of holes, forming the panel into a preselected curve about a longitudinal centerline, forming the leading edge portion of the panel into a front flange, forming a shoulder in the panel centered on the holes and extending perpendicularly from a surface thereof, bending an outer portion of the shoulder into a lip, and bonding the portions of the panel comprising the shoulder and lip.