Robotic deep rolling tool design for mechanical surface treatment of extremely complex and tight clearance 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; a roller disk support attached to the roller end, the roller disk support comprising a pair of forks; a roller disk joined to the pair of forks, 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;   a roller disk support attached to the roller end, the roller disk support comprising a pair of forks;   a roller disk joined to the pair of forks, 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 , further comprising:
 an interlock feature configured to mate the roller disk support with the arm proximate the roller end.   
     
     
         3 . The system for deep rolling a fan blade according to  claim 2 , wherein a connector portion formed in the roller disk support comprises two branches that span apart in a Y shape forming the interlock feature. 
     
     
         4 . The system for deep rolling a fan blade according to  claim 1 , wherein the roller disk support comprises an axle spanning between the pair of forks configured to support the roller disk. 
     
     
         5 . The system for deep rolling a fan blade according to  claim 1 , wherein the roller disk support comprises at least one fluted portion extending distally from the roller disk receiver to a bore formed in a connector portion opposite the pair of forks. 
     
     
         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 pair of forks comprise an outer surface that is hemispherical shaped and has a low profile configured to prevent contact with the workpiece. 
     
     
         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 support attached to the roller end, the roller disk support comprising a pair of forks;   a roller disk joined to the pair of forks, 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 roller disk support comprises 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. 
     
     
         10 . The system for deep rolling a fan blade according to  claim 9 , wherein a connector portion formed in the roller disk support comprises two branches that span apart in a Y shape forming the interlock feature. 
     
     
         11 . The system for deep rolling a fan blade according to  claim 8 , wherein the roller disk support comprises an axle spanning between the pair of forks configured to support the roller disk. 
     
     
         12 . The system for deep rolling a fan blade according to  claim 8 , wherein the pair of forks comprise an outer surface that is hemispherical shaped and has a low profile configured to prevent contact with the fan blade. 
     
     
         13 . The system for deep rolling a fan blade according to  claim 8 , wherein the roller disk support comprises at least one fluted portion extending distally from the roller disk receiver to a bore formed in a connector portion opposite the pair of forks. 
     
     
         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;   attaching a roller disk support to the roller end, the roller disk support comprising a pair of forks;   joining a roller disk to the pair of forks, 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:
 supporting an axle between the pair of forks; and   configuring the axle to support the roller disk.   
     
     
         16 . The process of  claim 14 , further comprising:
 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 outer surface that is hemispherical shaped on the pair of forks; and   configuring the outer surface with a low profile to prevent contact with the fan blade.   
     
     
         18 . The process of  claim 17 , further comprising:
 forming at least one fluted portion extending distally from a roller disk receiver to a bore formed in a connector portion opposite the pair of forks.   
     
     
         19 . The process of  claim 16 , further comprising:
 forming at least one bore in the roller disk support; and   configuring the at least one bore to accept a fastener configured to attach the roller disk support to the roller end of the arm.   
     
     
         20 . The process of  claim 14 , further comprising: forming a connector portion in the roller disk support, the connector portion comprises two branches that span apart in a Y shape forming an interlock feature.