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Methods and apparatus for manufacturing componentsRelated Patent Categories: Geometrical Instruments, Gauge, Collocating, AlignmentMethods and apparatus for manufacturing components description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070056180, Methods and apparatus for manufacturing components. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] This invention relates generally to manufacturing components, and more specifically to methods and apparatus for aligning components for manufacture. [0002] Accurate manufacturing of gas turbine engine components may be a significant factor in determining both manufacturing timing and cost. Specifically, when the component is a gas turbine engine blade, accurate manufacturing of the blade may be a significant factors affecting an overall cost of fabrication of the gas turbine engine, as well as subsequent modifications, repairs, and inspections of the blade. For example, at least some known gas turbine engine blades include a dovetail that typically requires an accurate machining process to create the dovetail profile and under platform surfaces. [0003] To align the dovetail for machining, the blade may be coupled to a fixture that includes at least one surface that locates a plurality of datums on the dovetail and/or other portions of the blade. Similar portions of different gas turbine blades may sometimes be machined on the same machine. However, generally, different engine blades have different datums due to a difference in a size and/or shape of the blades. Accordingly, different engine blades generally require different locating surfaces on the fixture to accurately align the blades for machining. As a result, the entire fixture, or alternatively an alignment member or a locating surface used with the fixture, may have to be replaced to accommodate different blades. However, replacing alignment members or the entire fixture may be time consuming, and thereby increase engine manufacturing cycle times and fabrication costs. BRIEF DESCRIPTION OF THE INVENTION [0004] In one aspect, a method is provided for aligning a first and a second component for manufacturing using an alignment member, wherein the first component includes at least one first datum and the second component includes at least one second datum. The method includes fixedly securing the alignment member to a fixture in a first orientation relative to the fixture, coupling the first component to the fixture such that the at least one first datum is aligned with a corresponding datum locator of a first datum nest of the alignment member, removing the first component from the fixture, repositioning the alignment member relative to the fixture from the first orientation to a second orientation relative to the fixture, fixedly securing the alignment member in the second orientation, and coupling the second component to the fixture such that the at least one second datum is aligned with a corresponding datum locator of a second datum nest of the alignment member. [0005] In another aspect, an alignment member is provided for aligning a first component and a second component with a fixture to facilitate manufacturing the first and second components. The alignment member includes a first datum nest including at least one first datum locator configured to locate a corresponding datum of the first component when the alignment member is fixedly secured to the fixture in a first orientation relative to the fixture, and a second datum nest including at least one second datum locator configured to locate a corresponding datum of the second component when the alignment member is fixedly secured to the fixture in a second orientation relative to the fixture. [0006] In even another aspect, an assembly for use in manufacturing a first component and a second component includes a fixture, and at least one alignment member for aligning the first and second components with the fixture. The alignment member includes a first datum nest including at least one first datum locator configured to locate a corresponding datum of the first component when the alignment member is fixedly secured to the fixture in a first orientation relative to the fixture, and a second datum nest including at least one second datum locator configured to locate a corresponding datum of the second component when the alignment member is fixedly secured to the fixture in a second orientation relative to the fixture. BRIEF DESCRIPTION OF THE DRAWINGS [0007] FIG. 1 is a perspective view of an exemplary gas turbine engine blade. [0008] FIG. 2 is a perspective view of another exemplary gas turbine engine blade. [0009] FIG. 3 is a perspective view of an exemplary embodiment of a fixture assembly for use in manufacturing a component, such as the gas turbine engine blades shown in FIGS. 1 and 2. [0010] FIG. 4 is a perspective view of the exemplary fixture assembly shown in FIG. 3. [0011] FIG. 5 is a perspective view of an exemplary embodiment of an alignment member for use with a fixture, such as the fixture shown in FIGS. 3 and 4. [0012] FIG. 6 is a perspective view of the exemplary alignment member shown in FIG. 5. [0013] FIG. 7 is a top plan view of the exemplary alignment member shown in FIGS. 5 and 6 in a first orientation relative to the fixture shown in FIGS. 3 and 4. [0014] FIG. 8 is a top plan view of the exemplary alignment member shown in FIGS. 5 and 6 in a second orientation relative to the fixture shown in FIGS. 3 and 4. DETAILED DESCRIPTION OF THE INVENTION [0015] As used herein, the terms "manufacturing" and "manufacture" may include any process for shaping and/or evaluating a component, such as, but not limited to fabrication and/or inspection. As used herein the terms "machining," "machine," and "machined" may include any process used for shaping a component. For example, processes used for shaping a component may include, but are not limited to including, turning, planing, milling, grinding, finishing, polishing, and/or cutting. In addition, and for example, shaping processes may include, but are not limited to including, processes performed by a machine, a machine tool, and/or a human being. The above examples are intended as exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the terms "machining," "machine," and "machined". [0016] As used herein, the terms "inspection" and "inspecting" may include any inspection process. For example, inspection processes may include measurement by a machine, measurement by humans, visual inspection by a machine, and/or visual inspection by a human. The above examples are intended as exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the terms "inspection" and "inspecting". In addition, as used herein the term "component" may include any object that has been or may be manufactured. [0017] FIG. 1 is a perspective view of an exemplary engine blade 10 that may be used with a gas turbine engine (not shown). In some embodiments, a plurality of turbine blades 10 form a high-pressure turbine rotor blade stage (not shown) within the gas turbine engine. Each blade 10 includes an airfoil 12 and an integral dovetail 14 that is used for mounting airfoil 12 to a rotor disk (not shown) in a known manner. Alternatively, blades 10 may extend radially outwardly from a disk (not shown), such that a plurality of blades 10 form a blisk (not shown). [0018] Each airfoil 12 includes a first contoured sidewall 16 and a second contoured sidewall 18. First sidewall 16 is convex and defines a suction side of airfoil 12, and second sidewall 18 is concave and defines a pressure side of airfoil 12. Sidewalls 16 and 18 are joined at a leading edge 20 and at an axially-spaced trailing edge 22 of airfoil 12. More specifically, airfoil trailing edge 22 is spaced chordwise and downstream from airfoil leading edge 20. First and second sidewalls 16 and 18, respectively, extend longitudinally or radially outward in span from a blade root 24 positioned adjacent dovetail 14, to an airfoil tip 26. In the exemplary embodiment, airfoil tip 26 includes a tip shroud 28 extending radially outward therefrom in a direction away from airfoil 12. A dovetail platform 30 is positioned at blade root 24 and extends radially outward from first and second sidewalls 16 and 18, respectively. [0019] FIG. 2 is a perspective view of another exemplary engine blade 32 that may be used with a gas turbine engine (not shown). In some embodiments, a plurality of turbine blades 32 form a high-pressure turbine rotor blade stage (not shown) within the gas turbine engine. Each blade 32 includes an airfoil 34 and an integral dovetail 36 that is used for mounting airfoil 34 to a rotor disk (not shown) in a known manner. Alternatively, blades 32 may extend radially outwardly from a disk (not shown), such that a plurality of blades 32 form a blisk (not shown). [0020] Each airfoil 34 includes a first contoured sidewall 38 and a second contoured sidewall 40. First sidewall 38 is convex and defines a suction side of airfoil 34, and second sidewall 40 is concave and defines a pressure side of airfoil 34. Sidewalls 38 and 40 are joined at a leading edge 42 and at an axially-spaced trailing edge 44 of airfoil 34. More specifically, airfoil trailing edge 44 is spaced chordwise and downstream from airfoil leading edge 42. First and second sidewalls 38 and 40, respectively, extend longitudinally or radially outward in span from a blade root 46 positioned adjacent dovetail 36, to an airfoil tip 48. In the exemplary embodiment, airfoil tip 48 includes a tip shroud 50 extending radially outward therefrom in a direction away from airfoil 34. A dovetail platform 52 is positioned at blade root 46 and extends radially outward from first and second sidewalls 38 and 40, respectively. Continue reading about Methods and apparatus for manufacturing components... Full patent description for Methods and apparatus for manufacturing components Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Methods and apparatus for manufacturing components patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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