Robotic deep rolling tool design for mechanical surface treatment of complex blade root geometry

Abstract

A system for deep rolling a workpiece including a roller tool comprising an adaptor plate proximate an adapter end; an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the workpiece; a roller disk joined to the roller end, the roller disk configured to contact the workpiece; and a fixture supporting the workpiece.

What is claimed is: 
     
         1 . A system for deep rolling a workpiece comprising:
 a roller tool comprising an adaptor plate proximate an adapter end;   an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the workpiece;   a roller disk joined to the roller end, the roller disk configured to contact the workpiece; and   a fixture supporting the workpiece.   
     
     
         2 . The system for deep rolling a fan blade according to  claim 1 , wherein the arm comprises at least one stiffener formed proximate the midspan portion. 
     
     
         3 . The system for deep rolling a fan blade according to  claim 1 , further comprising:
 a roller disk support attached to the roller end, the roller disk support comprising an interlock feature configured to mate with the arm proximate the roller end.   
     
     
         4 . The system for deep rolling a fan blade according to  claim 3 , wherein the roller disk support comprises an integral axel configured to support the roller disk. 
     
     
         5 . The system for deep rolling a fan blade according to  claim 3 , wherein the roller disk support comprises a tapered portion configured to reduce contact with the workpiece. 
     
     
         6 . The system for deep rolling a fan blade according to  claim 1 , wherein the roller disk support comprises at least one bore configured to accept a fastener configured to attach the roller disk to the roller end of the arm. 
     
     
         7 . The system for deep rolling a fan blade according to  claim 1 , wherein the arm comprises a curved feature formed along the arm proximate the roller end. 
     
     
         8 . A system for deep rolling a fan blade comprising:
 a roller tool comprising a dynamic force controller in operative communication with an adaptor plate proximate an adapter end;   an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with a root of the fan blade;   a roller disk joined to the roller end, the roller disk configured to contact the root; and   a fixture supporting the fan blade;   the fixture comprising:   a body including an upper region opposite a lower region, the body includes a front and a rear opposite the front, the body includes a right side and a left side opposite the right side;   the body supports a pivot clamp, the pivot clamp attaches to the body with a pivot attached to the body;   a support attached to the body, the support includes at least one brace coupled to the rear of the body, the support is configured to engage an airfoil portion of the fan blade;   a receiver formed in the body configured to support the root of the fan blade, wherein the receiver includes at least one landing configured to support a corresponding portion of the root; and   a shoulder attached to the body configured to support a platform portion of the fan blade; wherein the shoulder is located in an upper region of the body between the receiver and the support.   
     
     
         9 . The system for deep rolling a fan blade according to  claim 8 , wherein the arm comprises at least one stiffener formed proximate the midspan portion, the stiffener extending radially relative to a longitudinal axis of the arm. 
     
     
         10 . The system for deep rolling a fan blade according to  claim 8 , further comprising:
 a roller disk support attached to the roller end, the roller disk support comprising an interlock feature configured to mate with the arm proximate the roller end, the interlock feature comprising a concave surface configured to mate with a matching convex surface on the arm.   
     
     
         11 . The system for deep rolling a fan blade according to  claim 10 , wherein the roller disk support comprises an integral axel configured to support the roller disk. 
     
     
         12 . The system for deep rolling a fan blade according to  claim 11 , wherein the roller disk support comprises a tapered portion opposite the axel, the tapered portion configured to reduce contact with the fan blade. 
     
     
         13 . The system for deep rolling a fan blade according to  claim 10 , wherein the roller disk support comprises at least one bore configured to accept a fastener configured to attach the roller disk to the roller end of the arm. 
     
     
         14 . A process for forming a roller tool for deep rolling a fan blade comprising:
 the roller tool comprising an adaptor plate proximate an adapter end;   attaching an arm to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the fan blade;   joining a roller disk to the roller end, the roller disk configured to contact the fan blade; and   supporting the fan blade with a fixture.   
     
     
         15 . The process of  claim 14 , further comprising:
 forming at least one stiffener in the arm proximate the midspan portion; and   extending the stiffener radially relative to a longitudinal axis of the arm.   
     
     
         16 . The process of  claim 14 , further comprising:
 attaching a roller disk support to the roller end;   forming an interlock feature in the roller disk support; and   configuring the interlock feature to mate with the arm proximate the roller end; wherein the interlock feature comprises a concave surface configured to mate with a matching convex surface on the arm.   
     
     
         17 . The process of  claim 16 , further comprising:
 forming an integral axel in the roller disk support;   and configuring the integral axel to support the roller disk.   
     
     
         18 . The process of  claim 17 , further comprising:
 forming a tapered portion opposite the axel; and   configuring the tapered portion to reduce contact with the fan blade.   
     
     
         19 . The process of  claim 16 , further comprising:
 forming at least one bore in the roller disk support;   configuring the at least one bore to accept a fastener configured to attach the roller disk to the roller end of the arm.   
     
     
         20 . The process of  claim 14 , further comprising:
 forming an offset feature in the arm;   configuring the offset feature to enable the roller disc to contact with the fan blade at a working surface and avoid contact of the arm with the fan blade.