Photo By Michael A Furlano | FRCSW is taking a giant leap forward by replacing decades-old, inefficient equipment...... read more read more
In the world of military aviation and maritime power, every second counts and nowhere is that truer than at Fleet Readiness Center Southwest (FRCSW), where employees understand that maintaining Navy and Marine Corps aircraft and their associated components is critical to mission success. FRCSW is taking a giant leap forward by replacing decades-old, inefficient equipment with cutting-edge technology that dramatically boosts productivity, precision, and overall readiness.
The most recent example of this modernization effort is the introduction of the High Speed Blade Tip Grinder, a revolutionary machine that is transforming the repair process for the LM2500 engine, a vital powerplant that drives many Navy ships.
Elliot Kadota, an Industrial Engineer at FRCSW, has been a key player in this breakthrough. Industrial engineers like Elliot work hand-in-hand with artisans on the shop floor, providing technical oversight and engineering solutions that optimize the repair process.
The team’s focus has been the LM2500’s High Pressure Turbine (HPT) rotor, one of two critical rotors in the engine. The LM2500 engine’s High Pressure Compressor (HPC) compresses air entering the engine, which then mixes with fuel and combusts to generate power. The High Pressure Turbine (HPT), located downstream of the HPC, converts this energy to drive the compressor and ultimately propels Navy vessels.
Over time the HPT blades in an LM2500 engine experience wear, corrosion, and thermal damage, which can cause surface imperfections and dimensional changes thus requiring installation of new blades. These new blades must be grinded to meet necessary clearances and ensure the blades have optimal efficiency, balance, and durability.
Traditionally, grinding the HPT rotor blades was a labor-intensive, time-consuming endeavor. Using equipment that had been in service for over 20 years, artisans would spend up to 80 hours grinding the blades to precise specifications.
Enter the new High Speed Blade Tip Grinder (HSBTG), supplied by REFORM. This advanced machine performs grinding and laser measuring simultaneously, automatically stopping at the precise moment the blade meets quality standards. It also eliminates the need for shims, which the old machine required to prevent blade movement during grinding.
The HSBTG operates at an astonishing 1000 RPM, compared to the 5 RPM of its predecessor, the Mark III, thus the new grinder dramatically reduces turnaround times. The machine’s larger envelope allows it to encompass entire blades vice just a portion of each blade at a time, as was the process for the older unit’s smaller envelope. This increases throughput and ensures a superior finish. Additionally, the grinder performs a deburring step to remove any residual rough edges, ensuring blades meet the highest engineering standards.
The machine is also equipped with a virtual rotor system, allowing FRCSW personnel to input detailed blade profiles and grind specifications. This ensures the grinder performs every step (measurement, rough grind, brushing, final grind, and deburring) precisely and consistently without human intervention.
The results have been impressive. The grinder reduces HPT rotor turnaround from the previously stated 80 hours to just 3 hours, a staggering 97% reduction. This rapid processing allows artisans to focus on other critical repair tasks, significantly enhancing overall productivity at the command.
Recently, the team completed two HPT rotors in a single day for the first time ever, clearing backlogs and restoring engine readiness. The old machine, now serving as a backup, frequently broke down, halting production. The new grinder boasts higher reliability, minimizing downtime and risk.
Looking ahead, FRCSW is expanding this success to the more complex High Pressure Compressor (HPC) rotors, which feature 16 stages of blades and traditionally took over a month to grind on the old equipment. The new grinder is expected to cut that time to just 8 hours, effectively transforming a 30-day task into a single workday.
Embracing this state-of-the-art equipment, FRCSW is not only improving repair turnaround times but also raising the quality and precision of essential engine components. This leap in capability directly supports the Navy’s and Marine Corps’ operational readiness, ensuring their aircraft remain mission-capable when called upon.
FRCSW stands as a model of innovation and efficiency within military maintenance commands. The work done at the command exemplifies how smart engineering and modern technology can revitalize legacy programs and secure the future of naval aviation in support of the Presidents national defense strategy.
| Date Taken: | 08.21.2025 |
| Date Posted: | 08.21.2025 14:57 |
| Story ID: | 546167 |
| Location: | SAN DIEGO, CALIFORNIA, US |
| Web Views: | 41 |
| Downloads: | 0 |
This work, Fleet Readiness Center Southwest Revolutionizes Engine Repair, by Michael A Furlano, identified by DVIDS, must comply with the restrictions shown on https://www.dvidshub.net/about/copyright.
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