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.

What is claimed is: 
     
         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.