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Fixture Design and Process Development for High Pressure Compressor Rotor Blades Measuring in Turbofan Engine Maintenance
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A TAP Maintenance and Engineering disponibiliza serviços de manutenção para motores de aviação comercial. Para tal, os diversos componentes do motor são inspecionados com o intuito de realizar sua reparação e/ou substituição de forma a restaurar alguma da performance e eficiência no consumo de combustível do motor.
Nestes motores, acredita-se que o HPC (Compressor de Alta Pressão) tem um grande impacto na sua performance. Por isso, a oficina de motores da TAP tem grande interesse em adquirir conhecimentos mais aprofundados acerca da relação entre as pás do compressor de alta e os resultados de performance do motor em banco de testes.
O trabalho desenvolvido procura responder a esta necessidade, disponibilizando à oficina os meios necessários para uma inspeção detalhada das dimensões das pás do compressor de alta. Desta forma, engenheiros da TAP poderão adquirir a informação necessária para estudar a correlação descrita acima e consequentemente melhorar os processos de manutenção e reparação do compressor de alta.
Para este efeito, será necessária medição com recurso a uma CMM (Máquina de Medição de Coordenadas) dada a complexidade de algumas geometrias, o nível de precisão exigido por este estudo e ainda a quantidade elevada de pás que constituem o conjunto do rotor do compressor de alta. Assim o trabalho desenvolvido irá focar-se nas duas primeiras fases de implementação deste método de medição, sendo estas o desenvolvimento de modelos CAD de referência para as pás do compressor e o projeto de uma ferramenta de fixação de um conjunto de pás no plano de granito da CMM. Só depois, com base neste trabalho, será possível criar o programa de inspeção automático.
Os modelos CAD das pás foram desenvolvidos no software SolidWorks a partir de uma nuvem de pontos captada por um scanner 3D, foram depois usados como referência para o projeto da ferramenta e podem ainda vir a ser essenciais para a programação da inspeção através da CMM com recurso a modelos virtuais.
Adicionalmente, como a secção mais aprofundada desta tese, o projeto da ferramenta de fixação teve em conta tanto os requisitos de inspeção dimensional das pás como a própria manufatura da ferramenta. Assim, este trabalho irá também resultar na documentação necessária para a manufatura destas ferramentas permitindo à TAP iniciar o desenvolvimento do programa automático de inspeção das pás através da CMM
TAP Maintenance and Engineering provides repair and overhaul services for a commercial aircraft’s engines. For this, TAP’s shop disassembles and inspects the engine’s parts to determine which repairs and replacements should be performed in order to restore the engine’s performance and fuel efficiency and meet client’s requirements. In these engine’s, the HPC (High Pressure Compressor) is thought to have a large impact in the overall engine’s performance. Concerning this, TAP Engine’s shop has great interest in better understanding the correlation between the HPC Rotor blades and the engine’s performance which could improve the results of the engine’s overhaul. This work tries to answer this by providing the shop the means to perform detailed dimensional inspection for HPC Rotor blades which will provide TAP’s engineers real data necessary to perform a correlation study between the HPC blades’ condition and the engine’s efficiency. To achieve this, a CMM (Coordinate Measuring Machine) based inspection procedure would have to be implemented given the level of detail and the sheer number of blades assembled in the HPC rotor. The work developed focuses on the first two stages of this project, the development of CAD models of the blade from each compressor stage and the design of a fixture tool to display the blades for CMM inspection. The third stage, which is only introduced in the final segment of this work, corresponds to the development of the CMM’s automatic blade inspection program. The CAD models of the blades were developed in SolidWorks software based on a point cloud obtained from a 3D scanner. These models were then used to design the fixture tools and may be essential for the CMM programming using CAD data. The fixture tools were designed to meet the blade inspection functional requirements. This design, as the more in-depth segment of this work, was developed concerning both the blade inspection procedure using the CMM and the tool’s manufacturing. This work will result in the blade’s CAD models and the correspondent fixture tools’ files for manufacturing thus providing TAP Engine Shop with the initial framework to develop the CMM inspection program.
TAP Maintenance and Engineering provides repair and overhaul services for a commercial aircraft’s engines. For this, TAP’s shop disassembles and inspects the engine’s parts to determine which repairs and replacements should be performed in order to restore the engine’s performance and fuel efficiency and meet client’s requirements. In these engine’s, the HPC (High Pressure Compressor) is thought to have a large impact in the overall engine’s performance. Concerning this, TAP Engine’s shop has great interest in better understanding the correlation between the HPC Rotor blades and the engine’s performance which could improve the results of the engine’s overhaul. This work tries to answer this by providing the shop the means to perform detailed dimensional inspection for HPC Rotor blades which will provide TAP’s engineers real data necessary to perform a correlation study between the HPC blades’ condition and the engine’s efficiency. To achieve this, a CMM (Coordinate Measuring Machine) based inspection procedure would have to be implemented given the level of detail and the sheer number of blades assembled in the HPC rotor. The work developed focuses on the first two stages of this project, the development of CAD models of the blade from each compressor stage and the design of a fixture tool to display the blades for CMM inspection. The third stage, which is only introduced in the final segment of this work, corresponds to the development of the CMM’s automatic blade inspection program. The CAD models of the blades were developed in SolidWorks software based on a point cloud obtained from a 3D scanner. These models were then used to design the fixture tools and may be essential for the CMM programming using CAD data. The fixture tools were designed to meet the blade inspection functional requirements. This design, as the more in-depth segment of this work, was developed concerning both the blade inspection procedure using the CMM and the tool’s manufacturing. This work will result in the blade’s CAD models and the correspondent fixture tools’ files for manufacturing thus providing TAP Engine Shop with the initial framework to develop the CMM inspection program.
Descrição
Palavras-chave
Manutenção de Motores Turbofan Pás do Rotor do Compressor de Alta Inspeção Dimensional Ferramenta de Fixação Máquina de Medição de Coordenadas Turbofan Engine Maintenance High Pressure Compressor Rotor Blades Dimensional Inspection Fixture Tool Coordinate Measuring Machine