Fan Blades

The advanced tools and analysis from ZEISS can significantly improve traditional forging processes, resulting in increased productivity and higher accuracy rates on the first attempt.

The challenge
The die for the forging process is of paramount importance to the production of the fan blade. Ensuring the die and subsequent blades are conforming is where ZEISS technologies come in.

Our solution
ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity of the blades and the life and wear of the die.

Airfoil edge finishing takes the forged airfoil, often with "squared edges," to the finish leading and trailing edge shapes. At this point, it's also common to check the internal cavities of the blade, be it honeycomb or web structures, for their integrity.

The challenge
The combination of the twist, lean, and edge shape makes the measurement and inspection task very demanding. The impact of tiny features on the edges, compared to the size of the blade, is challenging. For internal characteristics, the blade size and material properties are demanding.

Our solution

• Digitally capture and analyze in 2D and 3D the conformity of the whole airfoil, including the intricate edges.
• ZEISS solutions measure the highest resolution and accuracy to analyze the edge: regular radius, elliptical shape, etc.
• ZEISS offers CT solutions for checking the internals.
  

The final machining ensures the part is fit for its intended final use. The tip clearances are critical to gas leakage to the casing and the root form for its precision fit to the fan disc.

The challenge
The overall size of the component, sometimes beyond 1.5 meters, in combination with the small tolerances on the root form, puts demands on selecting the right technology, probes, or sensors.

Our solution
The ZEISS solutions are complementary and can be used with tactile CMMs or ATOS ScanBox.

Regulatory and OEM requirements like AS9102 or AS13003 are necessary, stringent and comprehensive to fulfil.

The challenge
Fan blades are often deemed critical parts due to the impact if they fail in service, as such, the validation requirements to demonstrate airworthiness are some of the most demanding in the engine.

Our solution

• High-accuracy tactile, optical and microscopy solutions to fulfil thousands of characteristics necessary to validate
• ZEISS Quality Suite helps to compile the results in an effective way
• Specific software like Blade Inspect Pro enables to qualify every characteristic on part drawings or other standards in an efficient manner

Modern manufacturing techniques need to complement modern analysis techniques.
Carbon fiber fan blade processes are labor intensive and rely heavily on accurate shaping tools, and layup dies to produce the critical shape of the fan blade.

The challenge
The shaping die tool is critical to the creation of the overall shape of the blade and airfoil.
and needs regular checks for wear.

Our solution
ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the die's conformity and its life and wear over.

Once the fiber has been laid, the resin is added, giving the rigidity, and the part is cured to its final airfoil shape.

The challenge
The final parts change organically with any forming, molding, and shaping process.

Our solution
ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity to the part in the mold and when it's out to build the process understanding for long-term improvements.

The final machining of the root and tip is critical to performance and function. The root forms have small tolerance requirements to match perfectly with the disc, and the tip dimensions are essential to ensure no gas leakage between the blade and the casing, which would introduce inefficiencies in the engine performance.

The challenge
The overall size of the component, sometimes beyond 1.5 meters, in combination with the small tolerances on the root form, puts demands on selecting the right technology, probes, or sensors.

Our solution
ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity of the part in the mold and when it's out to build the process understanding for long-term improvements.

The metal leading edge is a work of art. A single piece of freeform geometry is carefully bonded to the main carbon blade.

The challenge
Verifying the complex external and internal shape on the metal edge is time-consuming and expensive, often requiring dedicated fixturing.

Our solution

• ZEISS optical technology allows measurement of the external shape and form and removes the need for hard fixturing due to features like virtual clamping.
• ZEISS tactile technologies additionally verify features with the highest accuracy.
  

Regulatory and OEM requirements like AS9102 or AS13003 are necessary, stringent, and comprehensive to fulfill.

The challenge
Fan blades are often deemed critical due to the impact if they fail in service; as such, the validation requirements to demonstrate airworthiness are some of the most demanding in the engine.

Our solution

• High-accuracy tactile, optical, and microscopy solutions fulfill thousands of characteristics necessary to validate.
• ZEISS Quality Suite helps to compile the results in an effective way.
• Specific software like ZEISS INSPECT Airfoil enables the efficient qualification of every characteristic on part drawings or other standards.