Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A method of designing a tool for forming a rotor blade including an airfoil portion includes generating a computer model of a rotor blade having an airfoil portion, and determining a curvature and radius of curvature at sections of the rotor blade. An inner and outer diameter of a circumferential forming portion of a tool operable to form the rotor blade may then be calculated. A method of designing a tool path for forming a rotor blade including an airfoil portion includes generating a computer model of a cylindrical tool operable to form a rotor blade including an airfoil portion and of a rotor having a plurality of the rotor blades. The computer models of the rotor and tool are used to generate a first and second tool motion corresponding to airfoil suction and pressure portions. A method of forming a rotor with integral blades is also disclosed.

Abstract: A machining system includes a support configured to retain an article, such as a rotor disk, having an area, such as a surface of a slot in the disk. A cutting tool, for example, a broach, is movable relative to the support to cut the area. A heating member, such as a laser, is configured to locally heat the area of the article. In one example, the cutting tool includes a body having a cutting edge. The heating member is supported by the body and is configured to provide heat adjacent to the cutting edge. The cutting edge cuts the locally heated area while the area is still heated.

Abstract: A method of machining a curved blade retention slot with electron discharge machining.

Abstract: A method of machining a blade retention slot with an abrasive water jet machining. A straight blade retention slot along an X-axis then a at least one side of the straight blade retention slot is abrasive water jet machined to generate a curved side of the blade retention slot defined within an X-Y plane.

Abstract: This disclosure relates to a design methodology used in manufacturing a broaching tool for cutting slots in aerospace disk applications. The method includes modeling geometry of the slot and the broach tool, which is based upon an initial minimum tooth rise that is determined empirically for the particular disk material. The number of broach inserts and teeth per insert is calculated, and the broach inserts are modeled. The stresses and deformation of the lug are calculated in a finite elements environment based upon simulated incremental broach tool movements. If the lug is not within specifications based upon design constraints, then the broach tool is revised and the simulations are repeated until the slot is within the desired specifications.

Abstract: A method of determining optimal parameters for machining a workpiece comprises performing a first computer simulation to determine parameters for machining a workpiece, including a tool nose radius and a tool rake angle, performing a second computer simulation to determine additional parameters for machining a workpiece, including a tool rotational speed and tool feed speed, and performing a third computer simulation to optimize the parameters for a desired tool path. A method of machining a green or bisque ceramic workpiece contacts the workpiece with a tool using a negative rake angle.

Abstract: A method of designing a tool for forming a rotor blade including an airfoil portion includes generating a computer model of a rotor blade having an airfoil portion, and determining a curvature and radius of curvature at sections of the rotor blade. An inner and outer diameter of a circumferential forming portion of a tool operable to form the rotor blade may then be calculated. A method of designing a tool path for forming a rotor blade including an airfoil portion includes generating a computer model of a cylindrical tool operable to form a rotor blade including an airfoil portion and of a rotor having a plurality of the rotor blades. The computer models of the rotor and tool are used to generate a first and second tool motion corresponding to airfoil suction and pressure portions. A method of forming a rotor with integral blades is also disclosed.