Method of remanufacturing a machine component

A method is provided for remanufacturing a machine component having multiple holes. The holes are provided to match in alignment with corresponding holes of an adjacent component in a machine assembly. First and second sets of holes are selected from the holes of the machine component on the basis of being located within first and second limits of positional tolerance with respect to corresponding holes of the adjacent component. Each hole from the first set of holes is bored to define openings in axial alignment with holes of the adjacent component. Each hole from the second set of holes is bored to an enlarged diameter and then plugged with a deformable insert. Each of these inserts is then drilled to define openings in axial alignment with holes of the adjacent component.

TECHNICAL FIELD

The present disclosure relates to a method of remanufacturing a machine component and more particularly to a method of remanufacturing a machine component having multiple holes that are to be matched with corresponding holes on an adjacent component of a machine assembly.

BACKGROUND

Manufacturers of machine components are continuously developing ways to re-use deformed machine components for fitment with associated machine assemblies. Accordingly, some methods have been developed in the past for configuring or re-configuring such deformed machine components.

For reference, U.S. Pat. No. 6,370,752 relates to a method for repositioning or repairing holes in metal substrates such as metal components used in jet engines and the like. The hole to be repositioned or repaired is enlarged and a recess is formed at each end of the enlarged hole. A deformable metal insert is inserted within the enlarged hole and then subjected to physical forces so as to cause it to deform and frictionally engage the walls of the recesses and the enlarged hole so that the insert becomes axially fixed therein. A new, repositioned hole can then be formed in the fixed insert that extends completely therethrough. However, such repositioning or repair of holes may not follow any pre-designed logic or strategy so as to accomplish the repair of holes in an optimal and/or efficient manner.

SUMMARY

In one aspect, the present disclosure provides a method for remanufacturing a machine component having multiple holes. The holes are to be matched with corresponding holes of an adjacent component in a machine assembly for co-axially receiving fasteners therein. The method includes selecting a first set of holes from the plurality of holes on the machine component. The method further includes boring each hole from the first set of holes to an enlarged diameter to define openings in axial alignment with holes of the adjacent component. The method further includes selecting a second set of holes from the plurality of holes on the machine component. The method further includes boring each hole from the second set of holes to an enlarged diameter. The method further includes plugging each of the bored second set of holes with a deformable insert. The method further includes drilling the inserts to define openings in axial alignment with holes of the adjacent component.

In another aspect, the present disclosure provides a method of configuring a deformed first flange for fitment onto a second flange, wherein the first flange defines holes that are axially offset from corresponding holes of the second flange. The method includes determining a first set of holes from the holes of the first flange that lie within a first limit of positional tolerance with respect to corresponding holes of the second flange.

The method further includes determining a second set of holes from the holes of the first flange that lie within a second limit of positional tolerance with respect to corresponding holes of the second flange. The method further includes boring the first and second sets of holes to an enlarged diameter. The bored first set of holes now axially align with corresponding holes of the second flange to receive fasteners therethrough. The method further includes plugging each of the bored second set of holes with a deformable insert. The method further includes drilling the inserts to define openings in axial alignment with corresponding holes of the second flange.

In yet another aspect, the present disclosure provides a method for remanufacturing a machine component having multiple holes. The holes are to be matched with corresponding holes of an adjacent component in a machine assembly for co-axially receiving fasteners therein. The method includes selecting a first hole from the plurality of holes on the machine component. The method further includes boring the first hole to an enlarged diameter to define an opening in axial alignment with a corresponding hole of the adjacent component.

The method further includes selecting a second hole from the plurality of holes on the machine component. The method further includes boring the second hole to an enlarged diameter. The method further includes plugging the bored second hole with a deformable insert. The method further includes drilling the insert to define an opening in axial alignment with a corresponding hole of the adjacent component.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to same or like parts. Moreover, references to various elements described herein are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular is also to be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.

FIG. 1shows a side view of an exemplary gas turbine engine100in accordance with an embodiment of the present disclosure. However, in alternative embodiments, other types of engines known in the art may be suitably employed in lieu of the gas turbine engine100ofFIG. 1. Some examples of engines that may be optionally used in place of the gas turbine engine100may include, but are not limited to, a reciprocating engine, a rotary engine or any other type of engine commonly known in the art.

Besides engines, the present disclosure may also be implemented in other structures typically used in various industrial applications. These structures may be static or dynamic structures depending upon the associated application. For example, the structures may be a pair of flanges that are mutually fastened to couple a pair of stationary or rotating members such as shafts. Therefore, although the present disclosure is explained in conjunction with the gas turbine engine100, one of ordinary skill in the art will acknowledge that embodiments of the present disclosure can be similarly applied to or implemented with other suitable structures known in the art.

Referring toFIG. 1, the gas turbine engine100includes an inlet system102, a compressor system104, a combustor system106, a turbine system108, and an exhaust system110. The inlet system102is configured to supply air to the compressor system104. The compressor system104may compress the supplied air and operatively provide the compressed air to various components of the combustor system106and the turbine system108, the compressed air also serving purposes in the gas turbine engine100such as, but not limited to, venting, and escaping through the exhaust system110. The compressor system104may be, but not limited to, a rotary compressor. Further, the compressor system104may be a single stage or a multistage compressor. As shown inFIG. 1, the compressor system104may embody a multistage rotary compressor.

The combustor system106may include multiple injectors112, and combustors114operatively connected to the injectors112. The injectors112may be adapted to receive compressed air from the compressor system104and supply a mixture of fuel and air to the combustors114. The combustors114combust the mixture of fuel and air to generate energy. This energy may be utilized to drive the turbine system108which may in turn use some part of the energy in driving the compressor system104while concurrently using the remaining part of the energy to do work.

The turbine system108and the exhaust system110may be coupled to each other. As shown inFIG. 1, the turbine system108and the exhaust system110define ends116,118that are located proximal to each other. The end118of exhaust system110is shaped in the form of a flange120. Similarly, the end116of the turbine system108is shaped into a flange122that is disposed in opposing relation with the flange120. These flanges120,122may include respective clocking or positional reference features Dt1, Dt2that are configured to correspond in alignment with each other. The positional reference features Dt1, Dt2may include for example, an interfitting pin and hole arrangement (as shown inFIG. 2), timing marks, or any other type of reference features that are required for the flanges120,122to be in mutual alignment with each other.

For simplicity and ease in understanding the present disclosure, reference to the flanges120,122of the exhaust system110and the turbine system108will be hereinafter made as the “first flange” and the “second flange” and designated with identical numerals120and122respectively.

The first flange120and the second flange122define co-axially aligned holes124,126that are configured to receive fasteners128therein. The fasteners128mutually couple the first flange120and the second flange122in a releasable manner. As shown inFIG. 2, the fasteners128may be, for example, a bolt and nut arrangement. The bolt130is located away from a periphery138of the first and second flanges120,122. The bolt130may define a bolt head configured to abut the first flange120while the nut140may be engaged with a threaded shank of the bolt130and positioned in abutment with the second flange122.

Although, the present disclosure is explained in conjunction with the bolt and nut arrangement, it may be noted that the bolt and nut arrangement is merely exemplary in nature and hence, non-limiting of this disclosure. Other suitable types of fasteners such as, but not limited to, rivets, grub screws, allen screws and the like may be alternatively employed in lieu of the bolt and nut arrangement disclosed herein.

FIG. 2shows a perspective view of the first and second flanges120,122with the matching hole pattern in a zoomed orthogonal view taken along section A-A′. Referring toFIG. 2, the holes124,126on the first and second flanges120,122are shown in axial alignment with each other. Moreover, the fasteners128are shown inserted in the axially aligned holes124,126of the first and second flanges120,122.

However, referring toFIG. 1, the combustors114also generate exhaust gases that are routed into the exhaust system110. These exhaust gases may be hot and are typically vented out with the help of the exhaust system110. One of ordinary skill in the art will acknowledge that the first flange120and/or other associated system hardware present in the exhaust system110may be subject to high temperatures resulting from the heat of the exhaust gases. As a result, a size and/or shape of the first flange120may be prone to deformation. Moreover, holes124present on the first flange120may be displaced from their initial or nominal positions with respect to the corresponding holes126of the second flange122, i.e., from co-axial positions with respect to the holes126of the second flange122.

Referring toFIG. 3, the first flange120is shown in an exemplary deformed state. As shown, a shape of the first flange120has undergone a change from an initial circular shape to an enlarged and/or oblong shape after a period of operation. One or more holes124of the first flange120are now axially offset with respect to the corresponding holes126of the second flange122. As such, referring toFIG. 3, the holes124on the first flange120have been displaced to varying degrees from their co-axial positions with respect to the corresponding holes126on the second flange122, as illustrated by the set of holes302and304.

The holes124of the first flange120may be displaced in one or more of a radially inward direction i.e., towards a center of the first flange120; a radially outward direction i.e., away from the center of the first flange120; a clockwise direction; or a counter clockwise direction, as indicated by the respective arrows M, N, O, and P inFIG. 3.

The diagrammatic representation ofFIG. 3is exaggerated to bring out a contrast in the displacement of positions of the holes124and126on the respective flanges120,122and thereby, improve the reader's clarity in understanding the present disclosure. One of ordinary skill in the art will acknowledge that the differences between the holes124,126may be practically less or more than that depicted inFIG. 3depending on actual conditions experienced by the flange120. Therefore, it should be noted that the diagrammatic representation ofFIG. 3is merely illustrative in nature and hence, non-limiting of this disclosure.

The present disclosure relates to a method400(shown inFIG. 4) of configuring the deformed first flange120for fitment onto the second flange122. Referring toFIG. 4, at step402, the method400includes selecting a first set of holes302from the holes124on the first flange120. The first set of holes302may be selected on the basis of a determination made regarding the amount of axial offset in the holes124of the first flange120relative to the corresponding holes126of the second flange122. In an embodiment, the holes124of the first flange120that lie within a first limit of positional tolerance Pt1with respect to the holes126of the second flange122may be regarded as the first set of holes302.

The first limit of positional tolerance Pt1, disclosed herein, may be a pre-defined tolerance limit. The first limit Pt1may be defined in relation to the clocking or positional reference feature Dt1. Moreover, the first limit Pt1may be defined based on, but not limited to, a minimum permissible edge distance between the hole124and a periphery138of the first flange120, a type of material forming the first flange120, an amount of force and stress with which the first and second flanges120,122are fastened, and other factors typically known to a person skilled in the art. As such, the force or torque with which the fasteners128secure the first and second flanges120,122may in turn depend on variables having minimum permissible values. The variable may include, but is not limited to, bolt stretch, surface contact between the flange and the bolt, and/or pre-load of the bolt.

For example, referring toFIG. 3, if a nominal diameter D of the first flange120is 1270 millimeters (50 inches), a nominal diameter d of each hole124of the first flange120is 16.764 millimeters (0.660 inches), and a nominal pitch circle diameter DPconsisting of centers of each hole124of the first flange120is 1193.8 millimeters (47 inches) so as to correspond with a similar arrangement and/or configuration of holes126on the second flange122, then a value of the first limit of positional tolerance Pt1may be set at ±0.1778 millimeters (±0.007 inches).

As illustrated inFIG. 3, the first limit of positional tolerance Pt1may define the maximum amount of displacement or axial offset of a hole124from its nominal or initial position for it to be categorically classified into the first set of holes302disclosed herein. This first limit of positional tolerance Pt1is applicable to the movement of a hole124in any direction/s i.e., radially inward direction M, radially outward direction N, clockwise direction O, and counter clockwise direction P. For example, if a hole124on the first flange120is displaced in the clockwise and radially outward direction i.e., P and N, to define an axial offset of 0.076 millimeters (0.003 inches) with its nominal position, then the hole124may be regarded as categorically falling within the first limit of positional tolerance Pt1and hence, may be considered to form part of the first set of holes302.

Referring again toFIG. 4, at step404, the method400further includes selecting a second set of holes304from the holes124on the first flange120. As with the first set of holes302, the second set of holes304are also selected on the basis of a determination made regarding the amount of axial offset in the holes124of the first flange120relative to the corresponding holes126of the second flange122. In an embodiment, if the holes124of the first flange120lie within a second limit of positional tolerance Pt2with respect to the holes126of the second flange122, then such holes124may be regarded as the second set of holes304.

The second limit of positional tolerance Pt2may be a pre-defined tolerance limit. As with the first limit of positional tolerance Pu, the second limit Pt2is also defined in relation to the clocking or positional reference feature Dn. Moreover, the second limit of positional tolerance Pt2may be set to a value greater than the first limit of positional tolerance Pt1. The second limit of positioning tolerance Pt2may be defined based on, but not limited to, a minimum permissible edge distance between the hole124and the periphery138of the first flange120, a type of material forming the first flange120, an amount of force and stress with which the first and second flanges120,122are fastened, and other factors typically known to a person skilled in the art. As such, the force or torque with which the fasteners128may secure the first and second flanges120,122in turn depend on variables having minimum permissible values such as, but not limited to, bolt stretch, surface contact, and/or pre-load of the bolt.

For example, referring toFIG. 3, if the nominal diameter D of the first flange120is 1270 millimeters (50 inches), the nominal diameter d of each hole124of the first flange120is 16.764 millimeters (0.660 inches), and the nominal pitch circle diameter Dpon the first flange120is 1193.8 millimeters (47 inches), then the second limit of positional tolerance Pt2may be set to a value of ±0.381 millimeters (±0.015 inches). Therefore, if a certain hole124of the first flange120has been displaced or axially offset, for example, by approximately 0.305 millimeters (approx. 0.012 inches), then the hole124is within the second limit of positional tolerance Pt2and hence, categorically forms part of the second set of holes304of the present disclosure.

A person having ordinary skill in the art will acknowledge that the first and the second limits of positional tolerance Pt1, Pt2disclosed herein are mutually exclusive of each other. The holes124may be displaced by a distance of between 0.001 to 0.4 times the nominal diameter d of the hole124. In the preceding example, where Pt1is ±0.178 millimeters (±0.007 inches), if a hole124on the first flange120is axially offset from its nominal position by, for example, 0.152 millimeters (0.006 inches), then such hole124may only be regarded as forming part of the first set of holes302alone although it is displaced by a distance that numerically lies within both the first and the second limits of positional tolerance Pt1, Pt2. Therefore, only if a hole124were displaced by a minimum of ±0.178 millimeters (±0.007 inches) or more (i.e., within a positional tolerance Pt2of ±0.381 millimeters or ±0.015 inches) from its nominal position, then such hole124would be considered to form part of the second set of holes304.

Referring back toFIG. 4, at step406, the method400includes boring each hole302from the first set of holes302to an enlarged diameter d1to define openings506(shown inFIG. 5) in axial alignment with corresponding holes126of the second flange122. Referring toFIG. 5, the hole302has been enlarged to define the opening506of diameter d1by performing a boring operation as known to one ordinarily skilled in the art.

It can be contemplated that an axis X used in boring the first set of holes302is kept axially aligned with respect to a centric axis Y of the corresponding holes126of the second flange122. This way, each hole302from the first set of holes302can be bored to define an opening506that is re-positioned in alignment with corresponding holes126of the second flange122. Therefore, the openings506of the first flange120are now axially aligned with the holes126of the second flange122and hence, may be configured to co-axially receive the fasteners128for e.g., the bolt130as shown inFIG. 1.

Turning back toFIG. 4, at step408, the method400further includes boring each hole304from the second set of holes304to an enlarged diameter d2. As shown inFIG. 6, the diameter d2to which a hole304from the second set of holes304is enlarged may be different from the enlarged diameter d1disclosed for the first set of holes302. Moreover, such enlargement of the second set of holes304may be performed keeping in mind the size of an insert608as will be explained later herein.

Referring toFIG. 4, at step410, the method400further includes plugging each of the bored second set of holes304with a deformable insert608. As shown inFIG. 6, the bored second set of holes304is plugged with deformable inserts608. The deformable inserts608may be, for example, pre-fabricated metal blanks, torque inserts or any other type of structures that are commonly known in the art to fill holes, voids or spaces in a given material.

The inserts608may be press-fitted into the bored second set of holes304. In one embodiment, the inserts608may be suitably sized to accomplish an interference fit or a transition fit with the bored second set of holes304. Alternatively, the second set of holes304(See step408ofFIG. 4, andFIG. 6) may be enlarged to a diameter d2depending on the type of fit required between the bored second set of holes304and the inserts608.

It may be acknowledged by a person ordinarily skilled in the art that the enlargement of the first and second set of holes302,304to the respective diameters d1, d2may be performed keeping in mind the amount of flange material available around the first and second set of holes302,304with the enlarged diameters d1, d2. Accordingly, a geometrical tolerance Gtmay be additionally applied when boring the first and second sets of holes302,304to the respective diameters d1, d2.

The geometrical tolerance disclosed herein may dictate the minimum amount of flange material that is required to be present around the first and second set of holes302,304. As such, the geometrical tolerance Gtmay define the value of diameters d1and d2to which the first set of holes302and the second set of holes304may be enlarged respectively such that the flanges120,122still continue to support the fasteners128or the inserts608adequately. Moreover, such geometrical tolerance Gtmay allow the flanges120,122to support the loads resulting during operation with use of the fasteners128or the inserts608.

The geometrical tolerance Gtmay be calculated based on many factors such as, but not limited to, a maximum permissible size of the hole124defined on the basis of the edge distance between the hole124and the periphery138of the first flange120, and a minimum area of contact required between the flange material and the fasteners128i.e., the bolts130or the nuts140. For example, as shown inFIG. 2, it is envisaged that in order to secure the flanges120,122adequately, a minimum area of surface contact may be required between the flange120and an underside of the bolt head. Any area of contact below the minimum calculated value may be impermissible as per operational parameters, design and/or other constraints of the first flange120. Additionally, such minimum area of surface contact between the flange120and the bolt head may be configured to support the amount of force with which the first and the second flanges120,122are fastened.

Moreover, as shown inFIG. 7, upon positioning the inserts608within the bored second set of holes304, the inserts608may be secured to the flange material. Hence, the inserts608may be prevented from executing axial and/or rotational movement within the bored second set of holes304. In an embodiment as shown inFIG. 7, locking pins702may be provided to assist in the securement of the insert608to the flange material. However, it is to be noted that the locking pins702, disclosed herein, are merely exemplary in nature and hence, non-limiting of this disclosure.

Alternatively or additionally, the inserts608may be welded or stitched to the adjacent flange material. Therefore, it may be noted that various methods are readily available to one of ordinary skill in the art and such methods and/or techniques may be equally implemented for locking the deformable inserts608within the bored second set of holes304without deviating from the spirit of the present disclosure.

Referring toFIG. 4, at step412, the method400further includes drilling the deformable inserts608to define openings810ofFIG. 8in axial alignment with the holes126of the second flange122. An axis Z used in drilling the inserts608is aligned with a centric axis Y of the corresponding holes126on the second flange122so that openings810formed in the inserts608are axially aligned with the corresponding holes126of the second flange122. Moreover, a size of a drill bit used in drilling the inserts608is selected as per the initial nominal diameters d of the holes124on the first flange120.

Referring toFIG. 8, the openings810defined in the inserts608are shown in axial alignment with holes126of the second flange122. Moreover, a size of the openings810corresponds to the nominal diameter d of the holes124on the first flange120. In this manner, each hole304from the second set of holes304can be bored, plugged, and drilled in the insert608to define an opening810that is re-positioned in alignment with corresponding holes126of the second flange122. Therefore, in this manner, the openings506from the first set of holes302and the openings810from the second set of holes304are now axially aligned with the holes126of the second flange122and hence, may be configured to co-axially receive the fasteners128therein.

It is to be noted that in various embodiments of the present disclosure, the axes X, Z of boring and/or drilling used for re-positioning the holes124of the first flange120are co-axially aligned with the centric axes Y of the holes126on the second flange122. However, in alternative embodiments, it is contemplated to re-position the displaced holes124of the first flange120to positions as defined in an associated engineering drawing so that the resulting re-positioned openings506,810are matched in alignment with the holes126of the second flange122.

FIG. 9illustrates a method900of configuring the deformed first flange120for fitment onto the second flange122of the exemplary gas turbine engine100ofFIG. 1in accordance with another embodiment of the present disclosure. At step902, the method900includes determining the first set of holes302from the holes124of the first flange120that lie within the first limit of positional tolerance Pt1with respect to corresponding holes126of the second flange122. At step904, the method900further includes determining the second set of holes304from the holes124of the first flange120that lie within the second limit of positional tolerance Pt2with respect to corresponding holes126of the second flange122.

At step906, the method900further includes boring the first and second set of holes302,304, to the respective enlarged diameters d1, d2. The enlarged diameter d1of the first set of holes302and the enlarged diameters d2of the second set of holes304may be similar or dissimilar depending on the sizes of the fasteners128and the inserts608.

As disclosed earlier herein, in one embodiment, the first limit of positional tolerance Pt1may be less than the second limit of positional tolerance Pt2. Boring the first set of holes302to the enlarged diameter d1disposes the bored first set of holes302in axial alignment with corresponding holes126of the second flange122. The bored first set of holes302together with the corresponding holes126of the second flange122may then allow insertion of the fasteners128therethrough.

At step908, the method900ofFIG. 9further includes plugging each of the bored second set of holes304with the deformable insert608. At step910, the method900further includes drilling the inserts608to define the openings810in axial alignment with corresponding holes126of the second flange122. Thereafter, the openings810and the corresponding holes126are axially aligned and hence, may be configured to receive the fasteners128therethrough.

In an embodiment of the present disclosure, the second set of holes304may be selected on the basis of the holes124being located outside the first limit of positional tolerance Pt1with respect to the corresponding holes126of the second flange122. Therefore, in this embodiment, the second limit of positional tolerance Pt2may not be present or used for the determination of the second set of holes304from the holes124on the first flange120.

In an example as shown inFIG. 10, if a hole124is located substantially far from the periphery138, or from adjacent holes124of the first flange120, then a very large value in the second limit of positional tolerance Pt2may be permitted in the displacement of such hole124. Also, in another example as shown inFIG. 10, if a nominal diameter d of a hole124on the flange is significantly smaller than the diameter D of the flange itself, then a large value of second limit Pt2may be applicable to such hole124. As such, the holes124of the first flange120may be displaced to a distance of between 0.001 to 0.4 times of their respective diameters d. Therefore, even if the hole124may be located close to the periphery138of the flange, the significantly small diameter d of the hole124may result in a large value of the second limit of positional tolerance Pt2.

Referring toFIG. 10, if a nominal position of the holes124is far away from the periphery138of the first flange120, or if the diameters d of the holes124are negligible in comparison with the diameter D of the first flange120, then the second limit of positional tolerance Pt2may be practically large in value. Therefore, one of ordinary skill in the art may acknowledge that it is possible to omit a large second limit of positional tolerance Pt2when determining the second set of holes304from the holes124of the first flange120.

In such cases, the first limit Pt1alone may be used in the determination of the first set of holes302and the second set of holes304as well. If the holes124of the first flange120are displaced or axially offset to a distance within the first limit of positional tolerance Pt1, then such holes124may be regarded as the first set of holes302. If the holes124are displaced outside of the first limit of positional tolerance Pt1, then such holes124may be regarded as the second set of holes304. Accordingly, the first set of holes302may be simply bored to the enlarged diameter d1and re-positioned in axial alignment with corresponding holes126of the second flange122. The second set of holes304may be bored, plugged with inserts608, and drilled in the inserts608to define the openings810in axial alignment with the corresponding holes126of the second flange122.

Therefore, depending on relative diameters d, D and positions of the first flange120and the holes124therein, the first limit Pt1alone, or both the first and second limits of positional tolerance Pt1, Pt2may be used to determine the first and second sets of holes302,304from the holes124of the first flange120. Moreover, the relative diameters d, D of the holes124and the first flange120forms the basis for the geometrical tolerance Gtdisclosed herein while the relative positions of the first flange120and the holes124form the basis for the first and second limits of the positioning tolerance Pt1, Pt2. Hence, one of ordinary skill in the art may acknowledge that although the second limit Pt2is disclosed herein, in cases of smaller sized holes124, or holes124that are located far away from the periphery138of the first flange120, the first and second sets of holes302,304may be determined using the first limit of positional tolerance Pt1alone.

Moreover, although the first and second sets of holes302,304disclosed herein are pursuant to a matching pattern or arrangement of the holes124,126on the first and second flanges120,122, the present disclosure is also applicable when one hole alone is displaced from its nominal position. Based upon its magnitude of displacement or axial offset, the hole124may be categorically classified as falling within the first limit of positional tolerance Pt1or within the second limit of positional tolerance Pt2. Optionally, in case of using the first limit of positional tolerance Pt1alone, such hole124may be classified as falling within or outside of the first limit of positional tolerance Pt1. Thereafter, embodiments of the present disclosure may be implemented to reposition the hole124and match such hole124in alignment with the corresponding hole126of the second flange122.

Further, it may be noted that although the present disclosure is explained in conjunction with the first and second flanges120,122of the gas turbine engine100, the first and second flanges120,122are merely exemplary in nature and non-limiting of this disclosure. The present disclosure may equally be applied to remanufacture various other types of machine components in a machine assembly in which holes of such machine components have to be matched in alignment to receive the fasteners128.

FIG. 11illustrates a method1100of remanufacturing a machine component1202(shown inFIG. 12) having multiple holes1204that are to be matched with corresponding holes1206of an adjacent machine component1208in a machine assembly1200. Referring toFIG. 12, exemplary machine components1202of the exemplary machine assembly1200are shown remanufactured using the method1100ofFIG. 11. The machine components1202and1208are configured for fitment into each other to form an exemplary machine assembly1200. As shown, the machine components1202,1208are in the shape of hollow boxes that are assembled to form a single large rectangular-shaped machine assembly1200.

Each of the machine components1202,1208is shown including two holes1204a,1204b, one of which may have been within the first limit of positioning tolerance Pt1, and the other of the holes1204a,1204bmay have been outside of the first limit of positioning tolerance Pt1. To that effect, each of the holes1204a,1204bhas been shown re-positioned using the method1100ofFIG. 11such that the individual hollow boxes are configured for fitment with each other in order to make up the box assembly.

Referring toFIG. 11, at step1102, the method1100includes selecting a first hole1204afrom the holes1204on the machine component1202. The first hole1204amay be categorically selected based on its current position falling within the first limit of positioning tolerance Pt1with respect to its nominal position.

At step1104, the method1100further includes boring the first hole1204ato an enlarged diameter d1to define an opening1212in axial alignment with a corresponding hole1206of the adjacent component1208.

At step1106, the method1100further includes selecting a second hole1204bfrom the holes1204on the machine component1202. At step1108, the method1100further includes boring the second hole1204bto an enlarged diameter d2. At step1110, the method1100further includes plugging the bored second hole1204bwith a deformable insert1214. Further, at step1112, the method1100further includes drilling the insert1214to define an opening1216in axial alignment with a corresponding hole1206of the adjacent component1208.

Various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All directional references (e.g., inward, outward, radial, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counter-clockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the devices and/or methods disclosed herein. Joinder references (e.g., attached, affixed, coupled, connected, and the like) are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.

Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any embodiment, variation and/or modification relative to, or over, another embodiment, variation and/or modification.

In methodologies directly or indirectly set forth herein, various steps and operations are described in one possible order of operation, but those skilled in the art will recognize that steps and operations may be rearranged, replaced, or eliminated without departing from the spirit and scope of the present disclosure as set forth in the claims.

It is to be understood that individual features shown or described for one embodiment may be combined with individual features shown or described for another embodiment. It is to be understood some features are shown or described to illustrate the use of the present disclosure in the context of functional segments and such features may be omitted within the scope of the present disclosure and without departing from the spirit of the present disclosure as defined in the appended claims.

INDUSTRIAL APPLICABILITY

The methods400,900,1100of the present disclosure have applicability for implementation and use in remanufacturing of various machine components such that the remanufactured machine components are configured for fitment with each other.

In some cases, manufacturers may encounter parts or components of a machine assembly that are adjacently located but with holes that may not necessarily match in alignment with each other. In other cases, although manufacturers initially configure the holes in alignment with each other, the machine components may undergo deformation after a certain period of operation thereby displacing the holes defined therein. As a result, the holes may move from their nominal positions and subject the fasteners to shear stress or fracture. It may be cumbersome to mutually align the holes of adjacent machine components by repairing a shape of the deformed flange. Moreover, such repair may be tedious, expensive, and time consuming to the manufacturer.

As an alternative solution, manufacturers may consider scrapping the deformed parts and may manufacture new parts or components altogether so that a fit, form, and function of such new parts or components may adhere to pre-defined engineering drawings and/or standards. However, manufacture of new parts may entail extensive labour, time, and effort thus decreasing overall profits to the manufacturer.

The methods400,900,1100of the present disclosure assist manufacturers in salvaging the deformed components by remanufacturing them in a simple and cost-effective manner. The methods400,900,1100disclosed herein allow manufacturers to repair the flange120by repositioning the holes124therein, without affecting or changing the initial alignment of the flanges120,122defined by their respective clocking or positional reference features Dt1, Dt2. Referring toFIGS. 3 and 12, if holes124,1204a,1204bon a particular component120,1202are to be matched in alignment with holes126,1206a,1206bon an adjacent component122,1208, an extent of the axial offset between the holes124,1204a,1204band the corresponding holes126,1206a,1206bis determined. The holes124,1204aare then classified as the first set of holes302or the second set of holes304depending upon the extent of axial offset from its respective nominal positions. The nominal positions disclosed herein are positions of the holes124,1204asuch that their respective centres co-axially align with centric axes Y of corresponding holes126,1206a, and1206bon the adjacent component122,1208.

As hole124,1204afalls within the first limit of positioning tolerance Pt1, such hole124,1204amay be merely bored to define the opening506having diameter d1such that the associated centre of such opening506is now re-positioned in axial alignment with the centric axis Y of the corresponding hole126,1206aon the adjacent machine component122,1208.

As hole124,1204bfalls within the second limit of positioning tolerance Pt2, then such hole124,1204bmay be bored to an enlarged diameter d2, plugged with an insert608, and then drilled in the insert608to define the opening810in axial alignment with the centric axis Y of the corresponding hole126,1206on the adjacent machine component.

However, when boring the displaced first and second set of holes302,304to the diameters d1, d2, the diameters d1, d2may be configured to lie within the permissible geometrical tolerances Gt. For example, referring toFIG. 5, although the openings506now align with the corresponding holes126on the second flange122, the openings506would not be sized so large as to cause them to close in or merge with the periphery138of the first flange120. Meanwhile, the openings506would also not be sized so large as to cause insufficient contact area of the flange material with the fasteners128, i.e., bolts130or nuts140, for example, with the underside of the bolt head as depicted inFIG. 1. Therefore, the methods400,900,1100disclosed herein take into account the positional tolerance and the geometrical tolerance Gtof the holes124,1204aon a given machine component120,1202when remanufacturing such machine component120,1202.

With implementation of the present methods, machine components may be remanufactured for mutual fitment in a simple and cost-effective manner. Moreover, a manufacturer may save significant time that is typically required in manufacturing a fresh or new component. Further, manufacturers may offset costs that were previously incurred with use of conventionally known methods or techniques. Furthermore, use of the methods disclosed herein may allow manufacturers to reduce carbon footprint as a result of salvaging the deformed machine components.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood that various additional embodiments may be contemplated by the modification of the disclosed machine, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.