Precision Sheet Fabrication for High-Performance Fan Blade and Disk Assemblies

Achieving a high-quality, consistent fit during operation requires precise sheet fabrication of each metal component in a four-piece assembly. This process involves the careful production of fan blades and discs. Each component presents unique challenges. Specialized techniques and expertise are required.

Fan Blade Production: Overcoming Manufacturing Challenges

To improve air intake efficiency, the customer designed a fan blade with four separate bends. Standardized tooling was used on the press brake. Costs associated with custom tooling were minimized. However, two major challenges emerged during the manufacturing process:

Managing Overbends and Underbends: Metal forming naturally results in overbends and underbends. It’s crucial to account for these variations in sheet fabrication to ensure the blades meet the design specifications.

Precise Tab Placement: Each fan blade includes four critical tabs that must be accurately sized and positioned to align with the disk’s corresponding slots.

Leveraging the capabilities of our CNC press brakes, our manufacturing technicians apply extensive material knowledge and manufacturing experience. Consistently matching the blade’s design drawing. Ensures optimal fit and function.

Disk Production: Precision Laser Cutting for Exact Slot Placement

The production of disks involves laser cutting precise slots which are crucial for the correct alignment with the fan blade tabs. The placement of these slots must meet tight tolerances to ensure flawless assembly and operation.

By adhering to Ultra’s prototyping standards, we refine the laser cutting process before full-scale production. This allows us to establish the correct programming for the fiber laser. Ensuring each disk is cut accurately to the design specifications. To maintain consistent quality, we perform a series of quality checks, including setup inspections and in-process assessments during laser production.

Ensuring Quality and Consistency in Every Assembly

By combining advanced sheet fabrication techniques, expert material handling, and rigorous quality control, we deliver high-performance fan blades and disks that consistently meet the required standards for precision and reliability.