Integrated tooling for abrasive flow machining

Abstract

A cluster-tool assembly for abrasive flow machining a plurality of airfoils is disclosed. The cluster-tool assembly comprises an airfoil cluster, the airfoil cluster including a supporting rail and the plurality of airfoils spaced about the supporting rail, and a sacrificial tool unitarily formed with the airfoil cluster, the sacrificial tool including a body and a plurality of prongs extending from the body.

What is claimed is: 
     
         1 . A cluster-tool assembly for abrasive flow machining of a plurality of airfoils, comprising:
 an airfoil cluster, the airfoil cluster including a supporting rail and the plurality of airfoils spaced about the supporting rail; and   a sacrificial tool unitarily formed with the airfoil cluster, the sacrificial tool including a body and a plurality of prongs extending from the body.   
     
     
         2 . The cluster-tool assembly of  claim 1 , wherein a first airfoil of the plurality of airfoils is positioned between a first prong and a second prong of the plurality of prongs. 
     
     
         3 . The cluster-tool assembly of  claim 2 , wherein the first airfoil includes a foil tip portion unitarily connected to the body of the sacrificial tool. 
     
     
         4 . The cluster-tool assembly of  claim 3 , wherein the first airfoil defines a length from a leading edge to a trailing edge and wherein a first side channel extends along the length between a convex foil surface of the first airfoil and a concave prong surface of the first prong. 
     
     
         5 . The cluster-tool assembly of  claim 4 , wherein a second side channel extends along the length between a concave foil surface of the first airfoil and a convex prong surface of the second prong. 
     
     
         6 . The cluster-tool assembly of  claim 5 , wherein the first prong includes a first prong tip portion positioned adjacent a first platform portion of the supporting rail, defining a first platform channel that extends along the length proximate a first base portion of the convex foil surface of the first airfoil. 
     
     
         7 . The cluster-tool assembly of  claim 6 , wherein the second prong includes a second prong tip portion positioned adjacent a second platform portion of the supporting rail, defining a second platform channel that extends along the length proximate a second base portion of the concave foil surface of the first airfoil. 
     
     
         8 . The cluster-tool assembly of  claim 6 , wherein the first side channel defines a channel width along the length, wherein the first platform channel defines a channel height along the length and wherein the channel height is greater than the channel width. 
     
     
         9 . The cluster-tool assembly of  claim 1 , wherein each one of the plurality of airfoils includes a foil tip portion unitarily connected to the body of the sacrificial tool and wherein each one of the plurality of airfoils is positioned between a first prong and a second prong. 
     
     
         10 . The cluster-tool assembly of  claim 9 , wherein each one of the plurality of airfoils includes a convex foil surface positioned adjacent a concave prong surface of the first prong and a concave foil surface positioned adjacent a convex prong surface of the second prong. 
     
     
         11 . The cluster-tool assembly of  claim 10 , wherein each one of the plurality of airfoils defines a length from a leading edge to a trailing edge and wherein a first side channel extends along the length between a first foil surface of each one of the plurality of airfoils and a first prong surface of an adjacent prong of the plurality of prongs. 
     
     
         12 . The cluster-tool assembly of  claim 9 , wherein each one of the plurality of airfoils defines a length from a leading edge to a trailing edge and wherein a first side channel extends along the length between a convex foil surface of each one of the plurality of airfoils and a concave prong surface of a first adjacent one of the plurality of prongs and wherein a second side channel extends along the length between a concave foil surface of each one of the plurality of airfoils and a convex prong surface of a second adjacent one of the plurality of prongs. 
     
     
         13 . An abrasive flow machine for polishing surfaces of a plurality of airfoils, comprising:
 a housing;   an abrasive media contained within the housing;   a driver operatively associated with the abrasive media to cause the abrasive media to flow over the surfaces of the plurality of airfoils; and   a fixture configured to retain a cluster-tool assembly within the flow of the abrasive media, the cluster-tool assembly comprising an airfoil cluster and a sacrificial tool unitarily formed with the airfoil cluster.   
     
     
         14 . The abrasive flow machine of  claim 13 , wherein the airfoil cluster comprises a supporting rail, wherein the plurality of airfoils is equally spaced about the supporting rail, and wherein the sacrificial tool comprises a body and a plurality of prongs extending from the body. 
     
     
         15 . The abrasive flow machine of  claim 14 , wherein each one of the plurality of airfoils includes a foil tip portion unitarily connected to the body of the sacrificial tool and wherein each one of the plurality of airfoils is positioned between a first prong and a second prong. 
     
     
         16 . The abrasive flow machine of  claim 15 , wherein each one of the plurality of airfoils includes a convex foil surface positioned adjacent a concave prong surface of the first prong and a concave foil surface positioned adjacent a convex prong surface of the second prong. 
     
     
         17 . A method for polishing surfaces of a plurality of airfoils, comprising:
 fabricating a cluster-tool assembly, the cluster-tool assembly including an airfoil cluster and a sacrificial tool unitarily formed with the airfoil cluster,
 wherein the airfoil cluster includes a supporting rail and the plurality of airfoils spaced about the supporting rail, wherein the sacrificial tool comprises a body and a plurality of prongs extending from the body, wherein a first airfoil of the plurality of airfoils is positioned between a first prong and a second prong of the plurality of prongs and wherein the first airfoil includes a foil tip portion unitarily connected to the body of the sacrificial tool; 
   positioning the cluster-tool assembly within an abrasive flow machine; and   flowing an abrasive media through a first side channel extending between a convex foil surface of the first airfoil and a concave prong surface of the first prong and a second side channel extending between a concave foil surface of the first airfoil and a convex prong surface of the second prong.   
     
     
         18 . The method of  claim 17 , wherein the first prong includes a first prong tip portion positioned adjacent a first platform portion of the supporting rail, defining a first platform channel that extends proximate a first base portion of the convex foil surface of the first airfoil and wherein the abrasive media is urged through the first platform channel. 
     
     
         19 . The method of  claim 18 , wherein the second prong includes a second prong tip portion positioned adjacent a second platform portion of the supporting rail, defining a second platform channel that extends proximate a second base portion of the concave foil surface of the first airfoil and wherein the abrasive media is urged through the second platform channel. 
     
     
         20 . The method of  claim 17 , further comprising terminating the flow of abrasive media and removing any portion of the sacrificial tool that remains connected to the airfoil cluster.