A virtual inspection framework for precision manufacturing of aerofoil components

The finite element method plays an extremely important role in forging process design as it provides a valid means to quantify forging errors and thereby govern die shape modification to improve the dimensional accuracy of the component. However, this dependency on process simulation could raise significant problems and present a major drawback if the finite element simulation results were inaccurate. This paper presents a novel approach to assess the dimensional accuracy and shape quality of aeroengine blades formed from finite element hot-forging simulation. The proposed virtual inspection system uses conventional algorithms adopted by modern coordinate measurement processes as well as the latest free-form surface evaluation techniques to provide a robust framework for virtual forging error assessment. Established techniques for the physical registration of real components have been adapted to localise virtual models in relation to a nominal Design Coordinate System. Blades are then automatically analysed using a series of intelligent routines to generate measurement data and compute dimensional errors. The results of a comparison study indicate that the virtual inspection results and actual coordinate measurement data are highly comparable, validating the approach as an effective and accurate means to quantify forging error in a virtual environment. Consequently, this provides adequate justification for the implementation of the virtual inspection system in the virtual process design, modelling and validation of forged aeroengine blades in industry.

Detection of Mixing Dynamics During Pumping of a Flooded Coal Mine

In complex hydrogeological environments the effective management of groundwater quality problems by pump-and-treat operations can be most confidently achieved if the mixing dynamics induced within the aquifer by pumping are well understood. The utility of isotopic environmental tracers (C-, H-, O-, S-stable isotopic analyses and age indicators—14C, 3H) for this purpose is illustrated by the analysis of a pumping test in an abstraction borehole drilled into flooded, abandoned coal mineworkings at Deerplay (Lancashire, UK). Interpretation of the isotope data was undertaken conjunctively with that of major ion hydrochemistry, and interpreted in the context of the particular hydraulic setting of flooded mineworkings to identify the sources and mixing of water qualities in the groundwater system. Initial pumping showed breakdown of initial water quality stratification in the borehole, and gave evidence for distinctive isotopic signatures (d34S(SO4) ~= -1.6‰, d18O(SO4) ~= +15‰) associated with primary oxidation of pyrite in the zone of water table fluctuation—the first time this phenomenon has been successfully characterized by these isotopes in a flooded mine system. The overall aim of the test pumping—to replace an uncontrolled outflow from a mine entrance in an inconvenient location with a pumped discharge on a site where treatment could be provided—was swiftly achieved. Environmental tracing data illustrated the benefits of pumping as little as possible to attain this aim, as higher rates of pumping induced in-mixing of poorer quality waters from more distant old workings, and/or renewed pyrite oxidation in the shallow subsurface.