Significantly enhancing conventional forging processes, ZEISS's state-of-the-art solutions and analysis have the potential to lead to heightened productivity and improved first-time accuracy rates ultimately.

The challenge
The die for the forging process is paramount to the production of the fan blade. ZEISS technologies ensure the die and subsequent blades conform.

Our solution
ZEISS technologies excel in digitally capturing and analyzing in 2D and 3D the conformity of the blades and the life and wear of the die, providing invaluable insights.

The process of airfoil edge finishing involves taking the forged airfoil, which often has "squared edges," and shaping the leading and trailing edges to their final form. At this stage, it is also typical to inspect the internal cavities of the blade, whether they are honeycomb or web structures, to ensure their integrity.

The challenge
Due to the twist, lean, and edge shape combination, the measurement and inspection task is very demanding. It is challenging to measure the impact of tiny features on the edges compared to the size of the blade. Additionally, the blade size and material properties make internal characteristic inspection 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 internal structure.
  

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, demands that the right technology, probes, or sensors be selected.

Our solution
The ZEISS solutions, known for their versatility, are complementary and can be effectively used with tactile CMMs or ATOS ScanBox, providing a comprehensive set of tools for the task at hand.

Regulatory and OEM requirements like AS9102 or AS13003 are comprehensive and stringent, demanding our utmost attention and adherence.

The challenge
Fan blades are often deemed critical parts due to the impact they would have if they failed 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 fulfill thousands of characteristics necessary to validate.
• ZEISS Quality Suite helps to compile the results effectively.
• Specific software like ZEISS INSPECT Airfoil efficiently qualifies every characteristic on part drawings or other standards.

Modern manufacturing techniques must align with modern analysis methods. Carbon fiber fan blades' production involves labor-intensive processes that rely heavily on accurate shaping tools, and layup dies to achieve the critical shape.

The challenge
Regular checks for wear on the shaping die tool are crucial. It's the key to maintaining the overall shape of the blade and airfoil.

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

Once the fiber is laid, the resin is added to provide rigidity, and the part is cured into its final airfoil shape.

The challenge
The final parts change naturally during forming, molding, or shaping.

Our solution
ZEISS technologies excel in digitally capturing and analyzing 2D and 3D conformance to the part in the mold. This process is instrumental in understanding and implementing long-term improvements.

The final machining of the root and tip is crucial for optimal performance and functionality. The root forms have small tolerance requirements to ensure a perfect match with the disc, while the tip dimensions are essential to prevent gas leakage between the blade and the casing. Such leakage would lead to inefficiencies in engine performance.

The challenge
The component's overall size, often exceeding 1.5 meters, along with the narrow tolerances on the root form, requires careful selection of the appropriate technology, probes, or sensors.

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

The metal leading edge is a masterpiece. It consists of a single piece of freeform geometry carefully bonded to the primary carbon blade.

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

Our solution

• ZEISS optical technology allows measurement of external shape and form and, due to features like virtual clamping, removes the need for hard fixturing.
• ZEISS tactile technologies, designed for efficiency, verify features with the highest accuracy, ensuring a reliable verification process.
  

Adhering to regulations and OEM requirements, such as AS9102 and AS13003, is essential for ensuring comprehensive compliance and high standards.

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

• The high-accuracy tactile, optical, and microscopy solutions satisfy numerous essential characteristics required for validation.
• ZEISS Quality Suite enables the valuable compilation of results.
• Specific software such as ZEISS INSPECT Airfoil enables efficient qualification of every characteristic on part drawings or other standards.