Abstract: A miniaturized turbogenerator (200) to directly provide electrical propulsion (307 308, 309) to small land, air, and maritime vehicles without an intervening electricity storage battery (315). The invention comprises of a process of miniaturization (500) of a turbine engine core (100), in particular its compressors and turbines (400), by means of hyper-feed machining by linear force alone, i.e. without rotation of either the workpiece or the cutting tool (505), and a resulting apparatus of a miniaturized turbogenerator (200) that has sufficient power density to provide high-performance electrical propulsion (310) for commercially feasible automobiles, urban air mobility vehicles, and other small vehicles and vessels with greater performance than battery-electric vehicles (300).

Abstract: A miniaturized turbogenerator (200) to directly provide electrical propulsion (307 308, 309) to small land, air, and maritime vehicles without an intervening electricity storage battery (315). The invention comprises of a process of miniaturization (500) of a turbine engine core (100), in particular its compressors and turbines (400), by means of hyper-feed machining by linear force alone, i.e. without rotation of either the workpiece or the cutting tool (505), and a resulting apparatus of a miniaturized turbogenerator (200) that has sufficient power density to provide high-performance electrical propulsion (310) for commercially feasible automobiles, urban air mobility vehicles, and other small vehicles and vessels with greater performance than battery-electric vehicles (300).

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-spindle CNC machining includes the steps of: fixturing a workpiece to the table of a non-spindle CNC holemaking machine tool. The cutting tool is then secured to the column of the machine tool and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole. The surface of the workpiece is approached with the cutting tool to a predetermined clearance level. Thereafter, the cutting tool is driven with sufficient linear force to induce instantaneous strain in the material of the workpiece to a depth necessary to create a hole of a desired size and shape using a drive mechanism. The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced.

Abstract: A method of hyper-feed machining the bladed components of turbomachines, and more specifically their bladed components. Hyper-feed machining, by means of the physical process of controlled fracturing, is the fastest, most precise, and nearest net shape method of machining in existence. The practical effects of the invention are: (1) the production of new and useful small-scale gas turbine engines for a wide range of previously impossible or impractical applications, and (2) the production of existing larger-scale gas turbine engines with great improvements in material removal rates by orders of magnitude, greater precision and geometric complexity of the bladed components, faster overall rates of production of these engines, and significantly reduced costs in production.

Abstract: A fully scalable turbomachine in which one or more of its components, in particular its bladed components, such as a blisk, is manufactured by controlled-fracture machining. The practical effects of the invention are (1) to improve the quality of current turbomachine components at greater rates of production and lower costs, (2) to increase the performance and the range of uses of current turbomachine functions, and (3) to enable new uses of turbomachines that are currently restricted by the lack of scalability and practicality in manufacturing. The most preferred embodiment of the invention is the gas turbine functioning as a jet engine or a turboshaft engine either for propulsion or for power generation.

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-spindle CNC machining includes the steps of: fixturing a workpiece to the table of a non-spindle CNC holemaking machine tool. The cutting tool is then secured to the column of the machine tool and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole. The surface of the workpiece is approached with the cutting tool to a predetermined clearance level. Thereafter, the cutting tool is driven with sufficient linear force to induce instantaneous strain in the material of the workpiece to a depth necessary to create a hole of a desired size and shape using a drive mechanism. The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced.

Abstract: A method for manufacturing a split link assembly having a split link (800C) that includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device (807). The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.

Abstract: A method for manufacturing a split link assembly having a split link (800C) that includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device (807). The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.

Abstract: A split link (800C) includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device (807) to form a split link assembly. The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.

Abstract: A non-spindle multi-axis machining center (600) and method for forming a part using a non-rotating cutting tool (400) for removing material from a non-rotating workpiece within a three-dimensional work envelope. The non-spindle machining center makes obsolete the use of mills for profiling operations without the need to rotate the cutting tool to produce sufficient torque to remove material. Instead, the cutting tool (400) applies a linear cutting force to the workpiece along a one-, two-, or three-dimensional cutting path with sufficient impact to remove material by means of controlled fracturing instead of plastic deformation. Also, without the need to rotate, neither the cutting tool nor the part are constrained in shape by axial symmetry. Therefore, parts without restrictions in shape can be produced with higher material removal rates and finer surface finishes than by milling or turning.

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-rotary machining includes the steps of fixturing a workpiece to the table of a non-rotary holemaking machine tool (103). The cutting tool is then fixtured to the column of the machine tool (105) and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole (107). The surface of the workpiece is approached with the cutting tool to a predetermined clearance level (109). Thereafter, the cutting tool is driven with sufficient force to induce instantaneous strain in the material of the workpiece to a depth necessary (111) to create a hole of a desired size and shape using a drive mechanism (113). The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced (117).

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-rotary machining includes the steps of fixturing a workpiece to the table of a non-rotary holemaking machine tool (103). The cutting tool is then fixtured to the column of the machine tool (105) and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole (107). The surface of the workpiece is approached with the cutting tool to a predetermined clearance level (109). Thereafter, the cutting tool is driven with sufficient force to induce instantaneous strain in the material of the workpiece to a depth necessary (111) to create a hole of a desired size and shape using a drive mechanism (113). The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced (117).

Abstract: An apparatus (100) and method (200) of contact machining having applications in profiling operations utilizes at least one static cutting tool (101) and turret (102) driven by rotary motion (103) about a support mechanism (109) for providing sufficient force to achieve deformation by controlled fracturing (523). This allows the separation of material from a workpiece (105) without imposing axial symmetry upon either the cutting tool (101) or the workpiece (105). The apparatus and method mitigates and/or eliminates the adverse effects of plastic deformation (504) while machining a wider range of shapes and materials with greater productivity and precision than existing methods of machining.

Abstract: An apparatus (100) and method (200) of contact machining having applications in profiling operations utilizes at least one static cutting tool (101) and turret (102) driven by rotary motion (103) about a support mechanism (109) for providing sufficient force to achieve deformation by controlled fracturing (523). This allows the separation of material from a workpiece (105) without imposing axial symmetry upon either the cutting tool (101) or the workpiece (105). The apparatus and method mitigates and/or eliminates the adverse effects of plastic deformation (504) while machining a wider range of shapes and materials with greater productivity and precision than existing methods of machining.

Abstract: A split link (800C) includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device(807) to form a split link assembly. The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.

Abstract: A non-rotary shaping method (700, 800, 900) and shaping center (600) for forming a part using a non-rotating cutting tool (400) for removing material from a non-rotating workpiece within a three-dimensional work envelope that obsoletes the use of mills for profiling operations. Without the need to rotate to produce sufficient surface footage to remove material, the cutting tool (400) applies constant cutting force to the workpiece along a one-, two-, or three-dimensional cutting path at a sufficiently high feed rate to remove material by means of controlled fracturing instead of plastic deformation. Also, without the need to rotate, neither the cutting tool nor the part are constrained in shape by axial symmetrical. Therefore, parts without any restriction in shape can be produced with finer surface finishes and higher material removal rates than by milling.

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-rotary machining includes the steps of fixturing a workpiece to the table of a non-rotary holemaking machine tool (103). The cutting tool is then fixtured to the column of the machine tool (105) and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole (107). The surface of the workpiece is approached with the cutting tool to a predetermined clearance level (109). Thereafter, the cutting tool is driven with sufficient force to induce instantaneous strain in the material of the workpiece to a depth necessary (111) to create a hole of a desired size and shape using a drive mechanism (113). The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced (117).

Abstract: The present invention is a wiper die assembly that combines the performance of a solid-body wiper die with the economy of a inserted wiper die for high-pressure rotary-draw tube-bending. The key features of the present invention are: [1] A wiper insert attached to the wiper holder by a mechanical means that retains the bore of the insert as a smooth, uninterrupted working surface, and [2] radius face support shoe attached to the wiper holder that can be adjusted to support and stabilize the entire wiper assembly against the cavity of the bend die.

Abstract: An apparatus (100) and method (200) of contact machining having applications in profiling operations utilizes at least one static cutting tool (101) and turret (102) driven by rotary motion (103) about a support mechanism (109) for providing sufficient force to achieve deformation by controlled fracturing (523). This allows the separation of material from a workpiece (105) without imposing axial symmetry upon either the cutting tool (101) or the workpiece (105). The apparatus and method mitigates and/or eliminates the adverse effects of plastic deformation (504) while machining a wider range of shapes and materials with greater productivity and precision than existing methods of machining.

Abstract: A non-rotary shaping method (700, 800, 900) and shaping center (600) for forming a part using a non-rotating cutting tool (400) for removing material from a non-rotating workpiece within a three-dimensional work envelope that obsoletes the use of mills for profiling operations. Without the need to rotate to produce sufficient surface footage to remove material, the cutting tool (400) applies constant cutting force to the workpiece along a one-, two-, or three-dimensional cutting path. Also, without the need to rotate, neither the cutting tool nor the part are constrained in shape by axial symmetrical. Therefore, parts without any restriction in shape can be produced with finer surface finishes and higher material removal rates than by milling.