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TASK 72-41-20-300-811
1 . Honeycomb Pre-Groove Machining.
A.This procedure gives instructions to repair the stage 10 outlet guide vane (OGV) by pre-groove machining the honeycomb. Refer to Figure 901.
NOTE:
This repair is referenced by TASK 72-00-00-800-818 (72-00-00, SPECIAL PROCEDURE 015).
B.There are no maximum repairable limits for this repair.
C.The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2303M16G04  
2303M16G06  
2303M16G07  
2303M16G08  
 
2763M05G02  
2763M05G03  
2763M05G04  
2763M05G05  
 
2763M05G06  
2763M05G07  
2763M05G08  
2763M05G09  
 
2763M05G10  
2763M05G11  
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D.Proprietary/Complex Process Statement.
(1)None.
2 . Tools, Equipment, and Materials.
NOTE:
Repair sources can use equivalent alternatives for tools, equipment, and consumable materials, however the repair source must demonstrate and document equivalency.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment. None.
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C10-155
Shims, Metal (shims)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-31-05
Engine Part Surface Integrity Acceptability Limits for Nontraditional Machined Surfaces
 
70-41-20
Cleaning 001
 
72-41-20
Repair 003
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-41-20-220-102
A.Refer to Figure 901 for specified dimensions and locations.
NOTE:
The dimensional data identified within this procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions, converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
4 . Setup Information.
Subtask 72-41-20-350-082
A.Set-up the OGV for machining/grinding as follows:
Subtask 72-41-20-930-006
(1)If necessary, make the machining fixture. Refer to Figure 902.
Subtask 72-41-20-350-083
(2)Install the machining fixture on the machining table as follows:
(a)Adjust the position of the machining fixture to get the runout of surface X to 0.001 inch (0.02 mm) FIR or less as follows:
1If necessary, put C10-155  shims between the machining fixture and the machining table to get the necessary runout.
(b)If necessary, adjust the position of the machining fixture to make sure that the runout of diameter Y is 0.001 inch (0.02 mm) FIR or less.
(c)Use four 0.500-13 UNC socket-head capscrews to hold the machining fixture to the machining table and as follows:
1Make sure that the runouts of surface X and diameter Y agree with the requirements specified in Subtask 72-41-20-350-083 (paragraph 4.A.(2)(a)) and Subtask 72-41-20-350-083 (paragraph 4.A.(2)(b)).
(3)Install the OGV onto the machining fixture as follows:
NOTE:
The OGV flange temperature can be decreased to help with its installation onto the machining fixture.
(a)Put the OGV onto the machining fixture and align the boltholes in the flange with the 17 threaded holes in the machining fixture.
(b)Attach the OGV to the machining fixture with seventeen 0.375-16 UNC bolts or screws.
(4)Make sure that you install the OGV flat on the machining fixture as follows:
(a)The maximum permitted clearance between surface X of the machining fixture and surface F of the OGV is 0.002 inch (0.05 mm).
5 . Procedure.
Subtask 72-41-20-350-085
A.Remove the three cover plates from the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
Subtask 72-41-20-320-018
B.Alternative Procedure Available. Machine the honeycomb seal pre-groove on diameter B. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901Figure 903, and do as follows:
NOTE:
Machining of the replaced honeycomb seal is done by electrolytically-assisted grinding (EAG) or electro-discharge machining (EDM). It is recommended to install a scrap OGV on the grinder. This will help give test parameters to record and use when you do the finish machining.
Subtask 72-41-20-350-084
(1)Set-up the OGV for machining. Refer to Subtask 72-41-20-350-082 (paragraph 4.A.).
Subtask 72-41-20-320-019
(2)Machine the honeycomb seal diameter B. Refer to TASK 70-31-05-220-001 (ENGINE PART SURFACE INTEGRITY ACCEPTABILITY LIMITS FOR NONTRADITIONAL MACHINED SURFACES), and as follows:
(a)The average recast layer permitted on the honeycomb seal surfaces is 0.002 inch (0.05 mm) or less.
(b)The maximum recast layer permitted on the honeycomb seal surface is 0.004 inch (0.10 mm).
(c)Micro-cracks are permitted in the recast layer only.
(d)The maximum intergranular attack permitted on the honeycomb surface is 0.0015 inch (0.038 mm) or less.
(e)Surface finish requirements do not apply to the machined honeycomb seal surfaces.
(f)Metal particles into the honeycomb cells are not permitted, unless it is as follows:
1Material that is not more than 0.002 inch (0.05 mm) built-up and is as follows:
aPerpendicular to the cell wall.
bIn the top 25 percent of the finished machined cell height.
(g)Metal particles that are on the surface adjacent to the honeycomb seal are not permitted.
Subtask 72-41-20-220-104
(3)Do a dimensional inspection of the honeycomb diameters and honeycomb runout while the OGV is in the fixture.
(4)Remove the OGV seal from the machining fixture.
Subtask 72-41-20-320-020
B.A.Alternative Procedure. Grind the honeycomb seal pre-groove on diameter B. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 903, and do as follows:
(1)Set-up the OGV for grinding. Refer to Subtask 72-41-20-350-082 (paragraph 4.A.).
Subtask 72-41-20-220-105
(2)Do a dimensional inspection of the honeycomb diameters and honeycomb runout while the OGV is in the fixture.
(3)Remove the OGV seal from the machining fixture.
Subtask 72-41-20-220-106
C.Do a visual inspection of the honeycomb seal for cells filled with remaining braze material as follows:
(1)Filled cells are not permitted unless they agree with the conditions that follow:
(a)All cells agree with a pin that measures 0.010 inch (0.25 mm) in diameter and 0.250 inch (6.35 mm) in depth.
(b)Filled cells are permitted in the forward end partial cell area or aft end partial cell area.
(c)If necessary, repair filled cells by EDM or with a jeweler's drill to make them agree with the limits as follows:
1No more than two percent of the honeycomb cells are repaired in a circumferential row.
2Repaired cells must agree with a pin that measures 0.010 inch (0.25 mm) in diameter and 0.250 inch (6.35 mm) in depth.
Subtask 72-41-20-440-007
D.Install the three cover plates onto the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
Subtask 72-41-20-160-013
E.If necessary, clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
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Figure NaN01   Stage 10 Outlet Guide Vane
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Figure NaN02   Machining Fixture
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Figure NaN03   (Sheet 1 ) Pre-Groove - Dimensional Information
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Figure NaN03   (Sheet 2 ) Pre-Groove - Dimensional Information