Engine Turbine Blade Removal Process Redesign
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Date
2015-12-07
Authors
Ahmed, Sarfraz
Castro, Rae
Huynh, Tung
Si, Machao
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Abstract
The purpose of this project is to design an improved rivet removal process for the client, StandardAero, which will ensure consistent alignment accuracy during drilling of the rivets. The client is StandardAero and the design team (Team 19) comprises four undergraduate students from the University of Manitoba’s Faculty of Mechanical Engineering. The team have used their collective engineering skills and experience developed over the past 4-5 years of education and related internship experience to design an alignment guide and fixture design that will provide for consistent alignment accuracy between the rivets. This design consists of two main components; a drill alignment guide and a redesigned disk mounting assembly. The alignment guide provides for initial alignment of the drill bit with the rivet bore on the turbine disk. The guide consists of a tubular shaft, with an outer diameter of 0.20” and length of 0.85”. It has an inner bore running through its length at a diameter of 0.074”. The guide also has a knurled handle with a diameter of 0.35”, and is perpendicular to the tubular shaft. The material specified for this guide is high strength polypropylene thermoplastic. The bottom end of the guiding shaft matches the shape of the chamfer that surrounds the rivet bore, and is designed to sit on the chamfer so that the inner bore is aligned with the rivet bore. The redesigned disk mounting assembly replaces the current bearing system with a motorized rotary stage, by ThorLabs Inc. Once the initial drill alignment is set, the rotary stage rotates the turbine disk to subsequent rivet bore positions by a specified distance, and ensures that movement is consistent throughout the drilling process. The rotary stage is run by a stepper motor which is controlled by a motor controller with pre-programmed software, allowing an operator to set the specified distance and control the rotary stage through a simple GUI menu on a PC workstation. The estimated cost of the redesigned fixture assembly (excluding the alignment guide) was determined to be approximately $4000. However, if the implementation of this design results in a reduction of even a […]