POLISHING BLADED ROTOR USING ROBOTIC POLISHING DEVICE

Abstract

A manufacturing method is provided that includes controlling a robotic polishing device, at a controller, to polish a plurality of first zones of a bladed rotor for an aircraft engine based on a first operating parameter associated with the robotic polishing device. An exterior of the bladed rotor includes the first zones and a plurality of second zones. The first zones are distributed circumferentially about an axis of the bladed rotor in a first array. The second zones are distributed circumferentially about the axis of the bladed rotor in a second array. The method further includes controlling the robotic polishing device, at a controller, to polish the second zones using the robotic polishing device based on a second operating parameter. The second operating parameter for the robotic polishing device is different than the first operating parameter.

Description

This application claims priority to U.S. Provisional Patent Application No. 63/435,476 filed Dec. 27, 2022, which is hereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates generally to an aircraft engine and, more particularly, to manufacturing a bladed rotor for the aircraft engine.

BACKGROUND INFORMATION

An aircraft engine may include one or more bladed rotors such as a propulsor rotor, a compressor rotor and a turbine rotor. Various systems and methods are known in the art for manufacturing a bladed rotor. While these known manufacturing systems and methods have various benefits, there is still room in the art for improvement.

SUMMARY

According to an aspect of the present disclosure, a manufacturing method is provided that includes controlling a robotic polishing device, at a controller, to polish a plurality of first zones of a bladed rotor for an aircraft engine based on a first operating parameter associated with the robotic polishing device. An exterior of the bladed rotor includes the first zones and a plurality of second zones. The first zones are distributed circumferentially about an axis of the bladed rotor in a first array. The second zones are distributed circumferentially about the axis of the bladed rotor in a second array. The method further includes controlling the robotic polishing device, at a controller, to polish the second zones using the robotic polishing device based on a second operating parameter. The second operating parameter for the robotic polishing device is different than the first operating parameter.

According to another aspect of the present disclosure, another manufacturing method is provided during which a bladed rotor for an aircraft engine is provided. An exterior of the bladed rotor includes a plurality of first zones and a plurality of second zones. The first zones are distributed circumferentially about an axis of the bladed rotor in a first array. The second zones are distributed circumferentially about the axis of the bladed rotor in a second array. Each of the first zones is polished using a robotic polishing device according to a first polishing process. Each of the second zones is polished using the robotic polishing device according to a second polishing process. An operating parameter for the robotic polishing device is different between the first polishing process and the second polishing process.

According to another aspect of the present disclosure, another manufacturing method is provided during which a first zone on an exterior of a component for an aircraft engine is polished using a robotic polishing device according to a first polishing process. A second zone on the exterior of the component is polished using the robotic polishing device according to a second polishing process. An operating parameter for the robotic polishing device is maintained during the first polishing process and the second polishing process, but different between the first polishing process and the second polishing process. The operating parameter comprises one of: an abrasive polishing belt tension; an abrasive polishing belt speed; a pressure exerted by the robotic polishing device against the component; an angle of inclination between a head of the robotic polishing device and the exterior of the component being polished; a tool path speed of the robotic polishing device along the exterior of the component; an offset between adjacent passes of the robotic polishing device along the exterior of the component; or a tool head configuration for the robotic polishing device.

According to still another aspect of the present disclosure, another manufacturing method is provided during which a first zone on an exterior of a bladed rotor for an aircraft engine is polished using a robotic polishing device according to a first polishing process. The bladed rotor includes a rotor disk and a plurality of rotor blades. The rotor blades are arranged circumferentially about and project out from the rotor disk. The first zone is on a first of the rotor blades. A second zone on the exterior of the bladed rotor is polished using the robotic polishing device according to a second polishing process. The second zone is on a portion of the rotor disk circumferentially adjacent the first of the rotor blades. An operating parameter for the robotic polishing device is maintained during the first polishing process and the second polishing process, but different between the first polishing process and the second polishing process.

The first zone may be contiguous with the second zone.

The first zone may be one of a plurality of first zones on the exterior of the component. Each of the first zones may be polished using the robotic polishing device according to the first polishing process. The second zone may be one of a plurality of second zones on the exterior of the component. Each of the second zones may be polished using the robotic polishing device according to the second polishing process. The second zones may be interspersed with the first zones circumferentially about an axis of the component.

The component may be a bladed rotor for the aircraft engine.

The robotic polishing device may include an abrasive polishing belt. The first operating parameter may be a first tension of the abrasive polishing belt. The second operating parameter may be a second tension of the abrasive polishing belt.

The robotic polishing device may include an abrasive polishing belt. The first operating parameter may be a first grit of the abrasive polishing belt. The second operating parameter may be a second grit of the abrasive polishing belt.

The robotic polishing device may include an abrasive polishing belt. The first operating parameter may be a first speed of the abrasive polishing belt. The second operating parameter may be a second speed of the abrasive polishing belt.

The first operating parameter may be a first pressure exerted by the robotic polishing device against the bladed rotor. The second operating parameter may be a second pressure exerted by the robotic polishing device against the bladed rotor.

The first operating parameter may be a first force exerted by the robotic polishing device against the bladed rotor. The second operating parameter may be a second force exerted by the robotic polishing device against the bladed rotor.

The first operating parameter may be a first angle of inclination between a head of the robotic polishing device and the exterior of the bladed rotor being polished. The second operating parameter may be a second angle of inclination between the head of the robotic polishing device and the exterior of the bladed rotor being polished.

The first operating parameter may be a first tool path speed of the robotic polishing device along the exterior of the bladed rotor. The second operating parameter may be a second tool path speed of the robotic polishing device along the exterior of the bladed rotor.

The first operating parameter may be a first offset between adjacent passes of the robotic polishing device along the exterior of the bladed rotor. The second operating parameter may be a second offset between adjacent passes of the robotic polishing device along the exterior of the bladed rotor.

The first operating parameter may be a first tool head configuration for the robotic polishing device. The second operating parameter may be a second tool head configuration for the robotic polishing device.

The robotic polishing device may have a first belt size and/or a first tool head size with the first tool head configuration. The robotic polishing device may have a second belt size and/or a second tool head size with the first tool head configuration. The second belt size may be different (e.g., wider) than the first belt size. The second tool head size may be different (e.g., wider) than the first tool head size.

The controlling of the robotic polishing device to polish the plurality of first zones may be further based on a third operating parameter for the robotic polishing device. The controlling of the robotic polishing device to polish the plurality of second zones may be further based on a fourth operating parameter for the robotic polishing device. The third operating parameter for the robotic polishing device may be different than the fourth operating parameter.

The controlling of the robotic polishing device to polish the plurality of first zones may be further based on a third operating parameter for the robotic polishing device. The controlling of the robotic polishing device to polish the plurality of second zones may be further based on a fourth operating parameter for the robotic polishing device. The third operating parameter for the robotic polishing device may be the same as the fourth operating parameter.

Each of the first zones may be polished before polishing any of the second zones.

A first of the first zones may axially neighbor a first of the second zones.

A first of the first zones may radially neighbor a first of the second zones.

A first of the first zones may circumferentially neighbor a first of the second zones.

A first of the first zones may be discrete from or may partially overlap a first of the second zones.

The bladed rotor may include a rotor disk and a plurality of rotor blades. The rotor blades may be arranged circumferentially about and project out from the rotor disk. Each of the first zones may be associated with a respective one of the rotor blades. Each of the second zones may be associated with a portion of the rotor disk between a respective circumferentially neighboring pair of the rotor blades.

The present disclosure may include any one or more of the individual features disclosed above and/or below alone or in any combination thereof.

The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an axial first end of a bladed rotor.

FIG. 2 is a schematic illustration of an axial second end of the bladed rotor.

FIG. 3 is a partial schematic sectional illustration of the bladed rotor taken along line 3-3 in FIG. 1.

FIG. 4 is a partial schematic sectional illustration of the bladed rotor taken along line 4-4 in FIG. 1.

FIG. 5 is a schematic illustration of a system for polishing the bladed rotor.

FIG. 6 is a schematic illustration of a set of various polishing device heads for the polishing system.

FIG. 7 is a sectional illustration of a set of various idler rollers for the polishing system.

FIG. 8 is a flow diagram of a method for manufacturing the bladed rotor.

FIG. 9 is a partial schematic illustration of a polishing device head polishing the bladed rotor.

FIG. 10 is a schematic illustration of sections of a tool path for polishing the bladed rotor.

DETAILED DESCRIPTION

The present disclosure includes systems and methods for manufacturing a bladed rotor for an aircraft engine. Herein, the term “manufacturing” may describe a process for forming and/or otherwise working on the bladed rotor to create (or during the creation of) a brand new bladed rotor. The term “manufacturing” may also or alternatively describe a process for overhauling (e.g., repairing) the bladed rotor to restore one or more features of a previously formed bladed rotor to brand new condition, similar to brand new condition or better than brand new condition. However, for ease of description, the manufacturing systems and methods may be described below with respect to creating the bladed rotor. Moreover, while the systems and methods are described below with respect to manufacturing the bladed rotor, it is contemplated these systems and methods may also be used to manufacture various other aircraft engine components or, more generally, various other aircraft components.

The bladed rotor may be any bladed rotor for the aircraft engine. The bladed rotor, for example, may be configured as a ducted rotor or an un-ducted rotor. Examples of the ducted rotor include, but are not limited to, a fan rotor, a compressor rotor and a turbine rotor. An example of the un-ducted rotor is a propeller rotor. The present disclosure, however, is not limited to the foregoing exemplary bladed rotor configurations and may be applicable to other air movers.

The bladed rotor may be configured for various aircraft engines. The bladed rotor, for example, may be configured for a geared gas turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section. Alternatively, the bladed rotor may be configured for a direct-drive gas turbine engine without a gear train. The gas turbine engine may include a single spool, two spools or more than two spools. The gas turbine engine may be configured as a turbofan engine, a turbojet engine, a turboprop engine, a turboshaft engine, a propfan engine, a pusher fan engine or any other type of gas turbine engine. The present disclosure, however, is not limited to gas turbine engine applications. The bladed rotor, for example, may alternatively be rotatably driven by various other types of thermal engines such as, but not limited to, a reciprocating piston internal combustion engine or a rotary internal combustion engine. Furthermore, the bladed rotor may alternatively be configured for non-thermal engine or hybrid applications where, for example, the bladed rotor is rotatably driven by an electric motor or a hybrid engine.

FIGS. 1-4 illustrate an exemplary embodiment of the bladed rotor 20. This bladed rotor 20 is rotatable about a rotational axis 22 of the bladed rotor 20, which rotational axis 22 may also be an axial centerline of the bladed rotor 20. The bladed rotor 20 includes a rotor disk 24 and a plurality of (e.g., integral) rotor blades 26; e.g., airfoils.

Referring to FIGS. 3 and 4, the rotor disk 24 extends axially along the rotational axis 22 between an axial first end 28 (e.g., a forward and/or upstream end) of the rotor disk 24 and an axial second end 30 (e.g., an aft and/or downstream end) of the rotor disk 24. The rotor disk 24 projects radially outward (away from the rotational axis 22) to an outer side 32 of the rotor disk 24. This disk outer side 32 forms an inner platform for the bladed rotor 20. The rotor disk 24 of FIGS. 1 and 2 extends circumferentially about (e.g., completely around) the rotational axis 22 providing the rotor disk 24 with a full-hoop body; e.g., a tubular or annular body.

The rotor blades 26 are distributed circumferentially about the rotor disk 24 and the rotational axis 22 in a circular array. Each of the rotor blades 26 is connected to (e.g., formed integral with, bonded to, etc.) the rotor disk 24. Each of the rotor blades 26 projects radially outward (away from the rotational axis 22) from the rotor disk 24 and its outer side 32. More particularly, referring to FIGS. 3 and 4, each rotor blade 26 projects spanwise out from the rotor disk 24 and its outer side 32 along a span line of the respective rotor blade 26 to a (e.g., unshrouded) tip 34 of the respective rotor blade 26. Each rotor blade 26 extends longitudinally along a camber line of the respective rotor blade 26 between a leading edge 36 of the respective rotor blade 26 to a trailing edge 38 of the respective rotor blade 26. Referring to FIGS. 1 and 2, each rotor blade 26 extends laterally across a thickness of the respective rotor blade 26 between opposing sides 40 and 42 of the respective rotor blade 26; e.g., pressure and suction sides of the respective rotor blade 26.

The bladed rotor 20 and its members 24 and 26 may be constructed from or otherwise include metal. Examples of the bladed rotor metal include, but are not limited to, aluminum (Al) or aluminum alloy, titanium (Ti) or titanium alloy, and metal superalloy (e.g., a nickel-chromium-based superalloy such as Inconel). The present disclosure, however, is not limited to the foregoing exemplary rotor metals.

FIG. 5 is a schematic illustration of an exemplary system 44 for polishing the bladed rotor 20. This polishing system 44 includes an automated robotic polishing device 46 and a controller 48 for automating operation of the robotic polishing device 46. Note, the controller 48 is generally described below as a single unit/system. The controller 48, however, may alternatively be implemented by a plurality of discrete controllers operated together. The controller 48, for example, may implement or may be separated into a robot controller and a programmable logic controller (PLC), with an HMI software that directs a polishing sequence.

The robotic polishing device 46 includes a robotic manipulator 50 and a polishing device head 52. The robotic manipulator 50 is configured to move and position the polishing device head 52 within a workspace 54. Briefly, the bladed rotor 20 is arranged within the workspace 54 for polishing, and may be attached to a support fixture (not shown) at a known or determinable location and/or spatial orientation. The robotic manipulator 50 is configured to move the polishing device head 52 within the workspace 54 such that the polishing device head 52 contacts an exterior 56 of the bladed rotor 20 and follows a tool path along the bladed rotor 20 during the polishing. The robotic manipulator 50, for example, may be configured as or otherwise include a single axis or multi-axis robotic arm (e.g., a six degree-of-freedom (DOF) robotic arm). The present disclosure, however, is not limited to such an exemplary robotic manipulator. Furthermore, it is contemplated the support fixture may also or alternatively be attached to another manipulator configured to move the bladed rotor 20 within the workspace 54 relative to the polishing device head 52. The support fixture, for example, may be attached to an external actuator which provides one or more additional degrees-of-freedom; e.g., an additional two degrees-of-freedom including rotation.

The polishing device head 52 is coupled to a distal end 58 of the robotic manipulator 50. The polishing device head 52 of FIG. 5 is configured to support and drive rotation of an abrasive polishing belt 60. The abrasive polishing belt 60, for example, may be wrapped around and supported by a drive roller 62 and an idler roller 64. The drive roller 62 is rotatably coupled to a motor 66; e.g., a pneumatic motor. This motor 66 may be arranged with (e.g., mounted to) the polishing device head 52. The motor 66 is configured to drive rotation of the abrasive polishing belt 60 by rotating the drive roller 62. The idler roller 64 is arranged at (e.g., on, adjacent or proximate) an unsupported, distal end 68 of the polishing device head 52. The polishing device head 52 may include a tensioning device 70 to adjust a relative position between the drive roller 62 and the idler roller 64. This tensioning device 70 may be a passive device comprising, for example, a preloaded spring. The preload of the spring may be selected to provide optimal tension for the abrasive polishing belt 60 when that belt 60 is new. With this arrangement, the preloaded spring may bias a rotational axis 72 of the drive roller 62 away from a rotational axis 74 of the idler roller 64 to tension the abrasive polishing belt 60.

The polishing device head 52 may be removably coupled to the robotic manipulator 50 by an actuatable coupler 76; e.g., an automated quick coupler. The robotic polishing device 46 may thereby readily attach and detach the polishing device head 52 from the robotic manipulator 50 during operation. With such an arrangement, the robotic polishing device 46 may be configured to utilize various different polishing device heads 52 (e.g., one at a time) during the polishing of the bladed rotor 20. The robotic polishing device 46, for example, may switch between different polishing device heads 52 in order to polish different zones of the bladed rotor 20 and/or perform different polishing operations.

FIG. 6 illustrates a set of different polishing device heads 52A and 52B (generally referred to as “52”) for the robotic polishing device 46. These polishing device heads 52 may generally have a common configuration except for, for example, a location of the motor 66. The motor 66 of the polishing device head 52A, for example, may be located to a first side 78 of the abrasive polishing belt 60. This may facilitate, for example, positioning a second side 80 of the abrasive polishing belt 60 (e.g., opposite the first side 78) close to a surface of the bladed rotor 20 (not visible in FIG. 6). By contrast, the motor 66 of the polishing device head 52B may be located to the second side 80 of the abrasive polishing belt 60. This may facilitate, for example, positioning the first side 78 of the abrasive polishing belt 60 close to a surface of the bladed rotor 20 (not visible in FIG. 6). The robotic polishing device 46, of course, may also or alternatively include various other polishing device heads 52 with alternative motor locations.

FIG. 7 illustrates the idler rollers 64A and 64B (generally referred to as “64”) for another set of different polishing device heads 52 for the robotic polishing device 46. These idler rollers 64 are provided with different configurations in order to change a contact patch between the abrasive polishing belt 60 and the bladed rotor 20 (not visible in FIG. 7). An outer surface 82A of the idler roller 64A, for example, may have a straight or substantially straight (e.g., slightly conical, curved, etc.) sectional geometry when viewed, for example, in a reference plane parallel with (e.g., that includes) the rotational axis 74 of the idler rotor 64A. This idler roller 64A may facilitate (relatively quick) polishing in open areas and/or polishing areas with flat or gently curved and/or otherwise non-flat surface geometries. By contrast, the outer surface 82B of the idler roller 64B may have an arcuate sectional geometry when viewed, for example, in the reference plane. This idler roller 64B may facilitate polishing in tight areas and/or polishing areas with curved and/or otherwise non-flat surface geometries. The present disclosure, however, is not limited to the foregoing exemplary different polishing device head configurations.

Referring to FIG. 5, the controller 48 is in signal communication (e.g., hardwired and/or wirelessly coupled) with the robotic polishing device 46. The controller 48, for example, may be in signal communication with the robotic manipulator 50 and/or the polishing device head 52. The controller 48 may be implemented with a combination of hardware and software. The hardware may include at least one processing device 84 and a memory 86, which processing device 84 may include one or more single-core and/or multi-core processors. The hardware may also or alternatively include analog and/or digital circuitry other than that described above.

The memory 86 is configured to store software (e.g., program instructions) for execution by the processing device 84, which software execution may control and/or facilitate performance of one or more operations such as those described in the methods below. The memory 86 may be a non-transitory computer readable medium. For example, the memory 86 may be configured as or include a volatile memory and/or a nonvolatile memory. Examples of a volatile memory may include a random access memory (RAM) such as a dynamic random access memory (DRAM), a static random access memory (SRAM), a synchronous dynamic random access memory (SDRAM), a video random access memory (VRAM), etc. Examples of a nonvolatile memory may include a read only memory (ROM), an electrically erasable programmable read-only memory (EEPROM), a computer hard drive, etc.

In some embodiments, the polishing system 44 may also include a force control device 87. The force control device 87 may be arranged along the robotic manipulator 50 proximate the polishing device head 52, between the robotic manipulator 50 and the polishing device head 52, or otherwise. This force control device 87 may be configured, for example, as an active contact flange including a pneumatic linear actuator (e.g., a bellow-type pneumatic linear actuator) or other linear actuator configured to translate along an axis (e.g., a single, linear axis) to control a position of the polishing device head 52 relative to an arm of the robotic manipulator 50. The force control device 87 may additionally include a compressor and/or a pressure control assembly (e.g., a pressure control valve) configured to control an air pressure within the pneumatic linear actuator and thereby control a linear position of the pneumatic linear actuator including a fully extended position, a fully retracted position or a plurality of intermediate linear positions between the fully extended position and the fully retracted position. The force control device 87 may additionally include a pressure sensor configured to measure an air pressure within the pneumatic linear actuator. The force control device 87 may also be in signal communication with the controller 48, for example, to facilitate positional control of the force control device 87 by the controller 48 and to transmit pressure measurements from the pressure sensor to the controller 48. The pressure measurements from the pressure sensor may facilitate calculation, by the controller 48, of force applied (e.g., to a workpiece) by the polishing device head 52. Exemplary configurations of the force control device 87 may include, but are not limited to, those sold under the ACF® trademark by FerRobotics Compliant Robot Technology GmbH (Austria).

FIG. 8 is a flow diagram of a method 800 for manufacturing the bladed rotor 20. For ease of description, the manufacturing method 800 is described with respect to the bladed rotor 20 of FIGS. 1-4 and the polishing system 44 of FIGS. 5-7. The manufacturing method 800 of the present disclosure, however, is not limited to manufacturing such an exemplary bladed rotor nor to using such an exemplary polishing system.

In step 802, the bladed rotor 20 is provided in a preform state; e.g., a substantially finished, but unpolished or semi-polished form. Herein, the term “preform” may describe a body that approximately or substantially has a common (the same) configuration (e.g., geometry, structural characteristics, etc.) as the component to be manufactured. For example, the bladed rotor provided during the step 802 may be a partially or completely unpolished version of the bladed rotor 20 of FIGS. 1-4 to be manufactured during the manufacturing method 800. The bladed rotor 20 (in its preform/unpolished state) may be formed using various manufacturing techniques. The bladed rotor 20, for example, may be cast, machined, additively manufactured and/or otherwise formed as a single monolithic body, or as separate bodies which are then welded and/or otherwise bonded together. The present disclosure, however, is not limited to such exemplary manufacturing techniques.

The exterior 56 of the bladed rotor 20 (in its preform/unpolished state) may be divided into a plurality of different zones. These zones may cover a portion (or alternatively an entirety) of the exterior 56 of the bladed rotor 20. The bladed rotor 20 of FIGS. 1-4, for example, may include one or more sets of zones 88A-F (generally referred to as “88”) at and/or along the axial first end 28 and/or one or more sets of zones 90A-F (generally referred to as “90”) at and/or along the axial second end 30. The zones 88, 90 in each set are distributed circumferentially about the rotational axis 22 in an array. The sets of zones 88 at the axial first end 28 may be circumferentially interspersed with one another. The zones 88A, 88D, 88C, 88E, 88B and 88F, for example, may be arranged in a sequentially repeating pattern circumferentially about the rotational axis 22. Similarly, the sets of zones 90 at the axial second end 30 may be circumferentially interspersed with one another. The zones 90A, 90D, 90C, 90E, 90B and 90F, for example, may be arranged in a sequentially repeating pattern circumferentially about the rotational axis 22. The zones 88A, 88B, 88C, 88D, 88E and 88F at the axial first end 28 may be disposed axially adjacent (e.g., axially contiguous with) the respective zones 90A, 90B, 90C, 90D, 90E and 90F at the axial second end 30. For example, each zone 88C-E extends axially from (or about) the axial first end 28 to a respective one of the zones 90C-E, and each zone 90C-E extends axially from (or about) the axial second end 30 to a respective one of the zones 88C-E. In another example, each zone 88A, 88B extends axially from (or about) a respective leading edge 36 to a respective one of the zones 90A, 90B, and each zone 90A, 90B extends axially from (or about) a respective trailing edge 38 to a respective one of the zones 88A, 88B.

Referring to FIG. 3, each zone 88A is located on the first side 40 (e.g., the pressure side) of a respective rotor blade 26. Each zone 88A, for example, extends axially (e.g., longitudinally) along the respective rotor blade 26 from a respective one of the zones 88F to a respective one of the zones 90A. Each zone 88A extends radially (e.g., spanwise) along the respective rotor blade 26 from a respective one of the zones 88D partially up the respective rotor blade 26 towards its blade tip 34. This zone 88A, for example, may span an inner fifth (⅕), an inner quarter (¼), an inner third (⅓) or an inner half (½) the span of the respective rotor blade 26. Of course, in other embodiments, it is contemplated each zone 88A may alternatively extend radially to the respective blade tip 34. Each zone 88A may have a substantially flat or slightly curved (e.g., concave) geometry. The term “slightly curved” may describe a curve with a relatively large radius of curvature.

Referring to FIG. 4, each zone 88B is located on the second side 42 (e.g., the suction side) of a respective rotor blade 26. Each zone 88B, for example, extends axially (e.g., longitudinally) along the respective rotor blade 26 from a respective one of the zones 88F to a respective one of the zones 90B. Each zone 88B extends radially (e.g., spanwise) along the respective rotor blade 26 from a respective one of the zones 88E partially up the respective rotor blade 26 towards its blade tip 34. This zone 88B, for example, may span an inner fifth (⅕), an inner quarter (¼), an inner third (⅓) or an inner half (½) the span of the respective rotor blade 26. Of course, in other embodiments, it is contemplated each zone 88B may alternatively extend radially to the respective blade tip 34. Each zone 88B may have a substantially flat or slightly curved (e.g., convex) geometry.

Referring to FIGS. 1, 3 and 4, each zone 88C is located on a portion of the rotor disk 24, at the disk outer side 32, circumferentially between a circumferentially neighboring pair of the rotor blades 26. Each zone 88C, for example, extends circumferentially along the rotor disk 24 between the circumferentially neighboring pair of the rotor blades 26 and, more particularly, a circumferentially neighboring pair of the zones 88D and 88E. Each zone 88C extends axially along the rotor disk 24 from the axial first end 28 to a respective one of the zones 90C. Each zone 88C may have a substantially flat or slightly curved (e.g., convex) geometry.

Referring to FIGS. 1 and 3, each zone 88D is located at an interface between the first side 40 of a respective rotor blade 26 and the rotor disk 24. Each zone 88D, for example, may cover a first portion of a fillet between the first side 40 of a respective rotor blade 26 and the rotor disk 24. Each zone 88D, for example, extends axially (e.g., longitudinally) along the respective rotor blade 26 from (or about) the axial first end 28 to a respective one of the zones 90D. Each zone 88D extends (e.g., radially and/or circumferentially) between a respective one of the zones 88A and a respective one of the zones 88C. Each zone 88D may have a relatively tightly curved (e.g., concave) geometry. The term “tightly curved” may describe a curve with a relatively small radius of curvature. For example, the radius of curvature of a slightly curved geometry may be at least five times (5×) or ten times (10×) the radius of curvature of a tightly curved geometry.

Referring to FIGS. 1 and 4, each zone 88E is located at an interface between the second side 42 of a respective rotor blade 26 and the rotor disk 24. Each zone 88E, for example, may cover a first portion of a fillet between the second side 42 of a respective rotor blade 26 and the rotor disk 24. Each zone 88E, for example, extends axially (e.g., longitudinally) along the respective rotor blade 26 from (or about) the axial first end 28 to a respective one of the zones 90E. Each zone 88E extends (e.g., radially and/or circumferentially) between a respective one of the zones 88B and a respective one of the zones 88C. Each zone 88E may have a relatively tightly curved (e.g., concave) geometry.

Referring to FIGS. 1, 3 and 4, each zone 88F is located at the leading edge 36 of a respective rotor blade 26. Each zone 88F, for example, extends laterally between and to a respective one of the zones 88A and a respective one of the zones 88B on a common (the same) rotor blade 26. Each zone 88F extends radially (e.g., spanwise) along the respective rotor blade 26 from or about the rotor disk 24 and/or the axial first end 28 partially up the respective rotor blade 26 towards its blade tip 34. This zone 88F, for example, may span an inner fifth (⅕), an inner quarter (¼), an inner third (⅓) or an inner half (½) the span of the respective rotor blade 26. Of course, in other embodiments, it is contemplated each zone 88F may alternatively extend radially to the respective blade tip 34. Each zone 88F may have a tightly curved (e.g., convex) geometry.

The zones 90A, 90B, 90C, 90D, 90E and 90F may be respectively configured and arranged similar to (but opposite of) the zones 88A, 88B, 88C, 88D, 88E and 88F. The zones 90A, 90B, 90C, 90D, 90E and 90F, for example, may have similar layouts, perimeters, sizes, etc. as the zones 88A, 88B, 88C, 88D, 88E and 88F, except for arranged at opposing axial ends of the bladed rotor 20. Of course, in other embodiments, the zones 90A, 90B, 90C, 90D, 90E and 90F may be configured and arranged in different manners than the zones 88A, 88B, 88C, 88D, 88E and 88F.

In step 804, the bladed rotor 20 is polished to provide a finished (e.g., polished) bladed rotor 20. Each of the zones 88, 90 in a respective set, for example, is polished using the robotic polishing device 46. This polishing may be performed set-after-set. For example, each of the zones 88A (or 90A) may be polished before polishing the zones 88B-F (or 90B-F), etc. Furthermore, each of the zones 88 to the axial first end 28 may be polished before polishing the zones 90 to the axial second end 30, or vice versa. With such a process, the robotic polishing device 46 may perform the same polishing process about the bladed rotor 20 before moving onto a different polishing process associated with another set of zones 88, 90. Of course, other embodiments, it is contemplated multiple zones 88 and/or 90 may alternatively be polished at a certain location before moving to another location circumferentially about the bladed rotor 20.

The polishing of the zones 88, 90 in each set may be performed by the robotic polishing device 46 according to a tailored polishing process for those zones in the set. For example, each of the zones 88A (or 90A) may be polished according to a common first polishing process, each of the zones 88B (or 90B) may be polished according to a common second polishing process, each of the zones 88C (or 90C) may be polished according to a common third polishing process, and so on. Each polishing process may include various operating parameters such as, but not limited to:

• • an abrasive polishing belt tension;
  • an abrasive polishing belt grit;
  • an abrasive polishing belt speed;
  • a pressure exerted by the robotic polishing device 46 against the bladed rotor 20 (e.g., a pressure of the abrasive polishing belt 60 against the exterior 56 of the bladed rotor 20);
  • an angle of inclination 92 (e.g., see FIG. 9) between the polishing device head 52 and the exterior 56 of the bladed rotor 20 at location being polished (e.g., contacted by the abrasive polishing belt 60);
  • a tool path speed of the robotic polishing device 46 and its polishing device head 52 along the exterior 56 of the bladed rotor 20;
  • an offset 94A, 94B (generally referred to as “94”) between adjacent passes of the robotic polishing device 46 and its polishing device head 52 along the exterior 56 of the bladed rotor 20 (e.g., see FIG. 10); and/or
  • a tool head configuration of the polishing device head 52 (e.g., a location of the motor 66; see FIG. 6) (e.g., a configuration of the idler roller 64; see FIG. 7) (e.g., a lateral width 95 of the abrasive polishing belt 60; see FIGS. 6 and 7) (e.g., a lateral width 97 of the polishing device head 52; see FIG. 6).

Any one or more or all of the foregoing operating parameters may be adjusted (e.g., changed) between some or all of the polishing processes. For example, any one or more of the operating parameters used during the polishing process for the zones 88A (or 90A) may be different than corresponding operating parameter(s) using during the polishing process for the zones 88B-F (or 90B-F). The polishing processes may thereby be tailored to the specific zones 88, 90 being polished in order to provide a certain surface finish for those respective zones 88, 90. This tailored zone approach may be useful where the exterior 56 of the bladed rotor 20 may be rougher in one or more of the zones 88, 90 than another one or more of the zones 88, 90 prior to the polishing. For example, where the exterior 56 of the bladed rotor 20 is relatively rough, the polishing process may utilize a courser abrasive polishing belt grit and a relatively fast tool path speed. The offset 94 between passes may also be decreased. However, where the exterior 56 of the bladed rotor 20 is relatively smooth, the polishing process may utilize a finer abrasive polishing belt grit and a relatively slow tool path speed. The offset 94 between passes may also be increased. The tailored approach may also be useful where the curvature of the exterior 56 of the bladed rotor 20 may be tighter in one or more of the zones 88, 90 than another one or more of the zones 88, 90. In such situations, the polishing device head 52 with the idler roller 64B of FIG. 7 may be utilized for tight curvatures whereas the idler roller 64A of FIG. 7 may be utilized for slight (e.g., gradual) curvatures or flat surfaces. The foregoing tailored zone approach may reduce processing time by performing some or all of the similar polishing operations (e.g., those for the zones 88A, 88B or 88C) before moving onto different polishing operations (e.g., those for the zones 88D, 88E or 88F). Note, in some embodiments, any one or more or all of the parameters may be held constant while polishing a zone. In other embodiments, any one or more or all of the parameters may be varied while polishing a zone.

While one or more of the operating parameters may be different between different polishing processes, one or more other of the operating parameters may be maintained (the same) during the different polishing processes. For example, the abrasive polishing belt speed may be maintained for polishing some or all of the zones 88, 90. In another example, the pressure exerted by the robotic polishing device 46 against the bladed rotor 20 may be maintained for polishing some or all of the zones 88, 90.

While various embodiments of the present disclosure have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the disclosure. For example, the present disclosure as described herein includes several aspects and embodiments that include particular features. Although these features may be described individually, it is within the scope of the present disclosure that some or all of these features may be combined with any one of the aspects and remain within the scope of the disclosure. Accordingly, the present disclosure is not to be restricted except in light of the attached claims and their equivalents.

Claims

1. A manufacturing method, comprising:

at a controller, controlling a robotic polishing device to polish a plurality of first zones of a bladed rotor for an aircraft engine based on a first operating parameter associated with the robotic polishing device;

wherein an exterior of the bladed rotor includes the plurality of first zones and a plurality of second zones, the plurality of first zones distributed circumferentially about an axis of the bladed rotor in a first array, and the plurality of second zones distributed circumferentially about the axis of the bladed rotor in a second array; and

at the controller, controlling the robotic polishing device to polish the plurality of second zones using the robotic polishing device based on a second operating parameter;

wherein the second operating parameter for the robotic polishing device is different than the first operating parameter.

2. The manufacturing method of claim 1, wherein

the robotic polishing device includes an abrasive polishing belt;

the first operating parameter comprises a first grit of the abrasive polishing belt; and

the second operating parameter comprises a second grit of the abrasive polishing belt.

3. The manufacturing method of claim 1, wherein

the robotic polishing device includes an abrasive polishing belt;

the first operating parameter comprises a first speed of the abrasive polishing belt; and

the second operating parameter comprises a second speed of the abrasive polishing belt.

4. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first pressure exerted by the robotic polishing device against the bladed rotor; and

the second operating parameter comprises a second pressure exerted by the robotic polishing device against the bladed rotor.

5. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first force exerted by the robotic polishing device against the bladed rotor; and

the second operating parameter comprises a second force exerted by the robotic polishing device against the bladed rotor.

6. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first angle of inclination between a head of the robotic polishing device and the exterior of the bladed rotor being polished; and

the second operating parameter comprises a second angle of inclination between the head of the robotic polishing device and the exterior of the bladed rotor being polished.

7. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first tool path speed of the robotic polishing device along the exterior of the bladed rotor; and

the second operating parameter comprises a second tool path speed of the robotic polishing device along the exterior of the bladed rotor.

8. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first offset between adjacent passes of the robotic polishing device along the exterior of the bladed rotor; and

the second operating parameter comprises a second offset between adjacent passes of the robotic polishing device along the exterior of the bladed rotor.

9. The manufacturing method of claim 1, wherein

the first operating parameter comprises a first tool head configuration for the robotic polishing device; and

the second operating parameter comprises a second tool head configuration for the robotic polishing device.

10. The manufacturing method of claim 1, wherein

the controlling of the robotic polishing device to polish the plurality of first zones is further based on a third operating parameter for the robotic polishing device;

the controlling of the robotic polishing device to polish the plurality of second zones is further based on a fourth operating parameter for the robotic polishing device; and

the third operating parameter for the robotic polishing device is different than the fourth operating parameter.

11. The manufacturing method of claim 1, wherein

the controlling of the robotic polishing device to polish the plurality of first zones is further based on a third operating parameter for the robotic polishing device;

the controlling of the robotic polishing device to polish the plurality of second zones is further based on a fourth operating parameter for the robotic polishing device; and

the third operating parameter for the robotic polishing device is the same as the fourth operating parameter.

12. The manufacturing method of claim 1, wherein each of the plurality of first zones are polished before polishing any of the plurality of second zones.

13. The manufacturing method of claim 1, wherein a first of the plurality of first zones axially neighbors a first of the plurality of second zones.

14. The manufacturing method of claim 1, wherein a first of the plurality of first zones radially neighbors a first of the plurality of second zones.

15. The manufacturing method of claim 1, wherein a first of the plurality of first zones circumferentially neighbors a first of the plurality of second zones.

16. The manufacturing method of claim 1, wherein

the bladed rotor includes a rotor disk and a plurality of rotor blades;

the plurality of rotor blades are arranged circumferentially about and project out from the rotor disk;

each of the plurality of first zones is associated with a respective one of the plurality of rotor blades; and

each of the plurality of second zones is associated with a portion of the rotor disk between a respective circumferentially neighboring pair of the plurality of rotor blades.

17. A manufacturing method, comprising:

polishing a first zone on an exterior of a component for an aircraft engine using a robotic polishing device according to a first polishing process; and

polishing a second zone on the exterior of the component using the robotic polishing device according to a second polishing process;

wherein an operating parameter for the robotic polishing device is maintained during the first polishing process and the second polishing process, but different between the first polishing process and the second polishing process; and

wherein the operating parameter comprises one of: an abrasive polishing belt tension; an abrasive polishing belt speed; a pressure exerted by the robotic polishing device against the component; an angle of inclination between a head of the robotic polishing device and the exterior of the component being polished; a tool path speed of the robotic polishing device along the exterior of the component; an offset between adjacent passes of the robotic polishing device along the exterior of the component; or a tool head configuration for the robotic polishing device.

18. The manufacturing method of claim 17, wherein the first zone is contiguous with the second zone.

19. The manufacturing method of claim 17, wherein

the first zone is one of a plurality of first zones on the exterior of the component, and each of the plurality of first zones is polished using the robotic polishing device according to the first polishing process;

the second zone is one of a plurality of second zones on the exterior of the component, and each of the plurality of second zones is polished using the robotic polishing device according to the second polishing process; and

the plurality of second zones are interspersed with the plurality of first zones circumferentially about an axis of the component.

20. A manufacturing method, comprising:

polishing a first zone on an exterior of a bladed rotor for an aircraft engine using a robotic polishing device according to a first polishing process, the bladed rotor including a rotor disk and a plurality of rotor blades, the plurality of rotor blades arranged circumferentially about and projecting out from the rotor disk, and the first zone on a first of the plurality of rotor blades; and

polishing a second zone on the exterior of the bladed rotor using the robotic polishing device according to a second polishing process, the second zone on a portion of the rotor disk circumferentially adjacent the first of the plurality of rotor blades;

wherein an operating parameter for the robotic polishing device is maintained during the first polishing process and the second polishing process, but different between the first polishing process and the second polishing process.