CN103223466A - Rapid metal die manufacturing method for turbine blades - Google Patents
Rapid metal die manufacturing method for turbine blades Download PDFInfo
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- CN103223466A CN103223466A CN201310132380XA CN201310132380A CN103223466A CN 103223466 A CN103223466 A CN 103223466A CN 201310132380X A CN201310132380X A CN 201310132380XA CN 201310132380 A CN201310132380 A CN 201310132380A CN 103223466 A CN103223466 A CN 103223466A
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Abstract
The invention discloses a rapid metal die manufacturing method for turbine blades. The method includes: designing a die structure, subjecting the structure to shell extraction by 3-5mm and removing the non-mating surface, using stereolithography equipment to prepare a die resin part, carrying out electric arc spraying to obtain a low-melting-point alloy with a thickness of 3-6mm, employing strong alkali corrosion to remove light-cured resin so as to obtain a metal die shell, assembling it with a metal conformal cooling pipeline obtained also by photocuring spraying corrosion, then conducting filling with metal powder and a melted low-melting-point solder mixture, carrying out curing and polishing, thus obtaining the die. The metal die is manufactured by combining photocuring rapid formation, electric arc spraying, resin corrosion and other technologies within 5-8 days, its precision can reach the CT4 grade, and the die has good thermal conductivity and high strength, thus ensuring uniform and rapid cooling of a wax die during formation.
Description
Technical field
The invention belongs to the Rapid tooling field, relate to a kind of metal die method for fast mfg towards turbo blade.
Background technology
Lost-wax process is a kind of method of model casting, wax-pattern surface is coated refractory material make shell, and melting can cast after the roasting at high temperature behind the mould dewax obtains precision casting.The foundry goods that model casting obtains can be realized near-net-shape, is widely used on the very high part of required precisions such as Aero-Space, automobile.In the lost-wax process casting, wax pattern is that the middle 3D shape of hot investment casting is transmitted part, and its quality has directly determined the precision of foundry goods.Turbo blade is that the engine operation environment is the most abominable, one of complicated parts of structure, and its manufacture method is the emphasis and the difficult point of industrial quarters always.The tradition hot investment casting is to adopt to press the wax-pattern tool to make wax pattern in batches, takes time and effort but use machine-tooled method to make metal die, and especially for the part that is used for labyrinth, making metal die needs a large amount of time and cost.
The photocureable rapid shaping technology has accuracy of manufacture height, can make the advantage of complicated inner cavity structure.Utilize the photocureable rapid shaping technology to transform, and then the quick Fabrication metal die is the effective way that shortens mold cycle, reduces manufacturing cost as intermediate state.
Conformal cooling pipe is the structure that Injection Mold Design will be considered, the conformal cooling duct of using the photocuring rapid prototyping technology can make resin material, because the thermal conductivity factor very low (less than 0.5W/ (m ℃)) of general resin material, resin die wax pattern cooling velocity is slow, cause the wax-pattern manufacturing cycle long, the thermal deformation of wax-pattern and mould is big, and the mass defect of wax-pattern is many in the cooling procedure, directly influences the hot investment casting casting quality.
Summary of the invention
The problem that the present invention solves is to provide a kind of metal die method for fast mfg towards turbo blade, combination by technology such as photocuring rapid prototyping, electric arc spraying, resin corrosion obtains the turbo blade metal die, save die manufacturing cost, can make complicated metal blade mould fast.
The present invention is achieved through the following technical solutions:
A kind of metal die method for fast mfg towards turbo blade may further comprise the steps:
1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, after mould structure is taken out shell 3~5mm and removed a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; Inner surface and the thick low-melting alloy of madial wall spraying 3~6mm at the resin mould spare of manufacturing obtain the metal die shell with resin corrosion back again;
2) design its conformal cooling pipe according to mould structure, use the photocuring rapid prototyping method to make the conformal cooling pipe resin piece then; At the thick low-melting alloy of the outer wall spraying 2~4mm of prepared cooling pipe resin piece, again resin corrosion back is obtained metal shape cooling pipe;
3) will obtain the assembling shell after metal die shell and the assembling of metal shape cooling pipe, in assembling shell cavity, fill the low melting point solder of thawing and the composite material of metal powder, fill up the assembling shell and evenly be coated with the surface flat; Cooling curing obtains metal die under normal temperature condition then, and is again that its surface finish is smooth.
The interior shape face of described male model, master mold is made repeatedly by the shape face of resin die;
Assemble again after male model and master mold prepared metal pattern respectively, form a complete metal die.
Described photocuring rapid prototyping method comprises: at first use delamination software that the resin die that designs is converted into plurality of thin layer plane graph data and be input in the photocureable rapid shaping machine; During photocuring rapid prototyping, use laser instrument successively to scan the liquid resin liquid level, the resin after successively solidifying constitutes needed resin die; Normal temperature following hardening time is 6-24h, is 3-12h 30-35 ℃ of condition following hardening time.
The light-cured resin that is adopted in the described photocuring rapid prototyping method, 30 ℃ of following viscosity are about 240cps when liquid, density 1.1~1.2g/cm
3, photocuring after-drawing intensity 45.4~45.7MPa, elastic modelling quantity 2460~2500MPa, shore hardness are that D is about 81.
Described spraying is electric arc spraying, and the low temperature gold that closes that spraying is used is the ZnAl alloy, and spray voltage is 28~30V in the spraying process, and electric current is 50~80A, air pressure 0.4-0.5MPa, sweep speed 8m/min, spray distance 200mm.
The fusing point of described low melting point alloy is lower than 200 ℃.
Described resin corrosion process is that resin is corroded 1~4h in chemical corrosion liquid, and light-cured resin is removed; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide.
The melting temperature of described low melting point solder will be lower than the melting temperature of the low-melting alloy that is sprayed, and the mass ratio of metal powder is 30~60% in the composite material.
Described composite material is filled under 180~220 ℃ of temperature, and the fusing point of low melting point solder is lower than 200 ℃; Described metal powder is copper powder, aluminium powder or iron powder; When the filling of mixed slurry, use the auxiliary grouting of vibratory equipment.
Described die size precision and surface quality are higher than the precision quality of target prepared product wax-pattern, keep assembling die shape size constancy shape simultaneously in the composite material perfusion; The described metal die rear surface of being polished is smooth, no bubble or projection.
Compared with prior art, the present invention has following beneficial technical effects:
The method for fast mfg of metal die provided by the invention, by the designing mould structure, structure is taken out shell 3-5mm and is removed non-mating surface, use photocuring moulding equipment to prepare SL resin mould spare, resin piece inner surface electric arc spraying 3-6mm low-melting alloy, use alkali corrosion to remove light-cured resin and obtain the metal die shell, assemble with the metal conformal cooling pipe that spraying corrosion behind the same photocuring obtains, fill the low melting point solder composite material of metal powder and thawing then, solidify the back polishing and obtain metal turbo blade mould.The metal die that combination by technology such as photocuring rapid prototyping, electric arc spraying, resin corrosion obtains, in 5-8 days, make metal die, its precision can reach the CT4 grade, and the mould thermal conductivity is good, intensity is higher, guarantees can evenly cool off fast when wax-pattern is shaped.
The method for fast mfg of metal die provided by the invention uses arc spraying technology can spray low-melting alloy on light-cured resin, and the intensity and the thermal conductivity of low-melting alloy are better.The erosion removal light-cured resin further reduces the thermal resistance of mould.The thermal conductivity of metal powder is better, and is mixing cured by these metal dusts and low melting point solder, and the mixture coefficient of heat conduction that obtains is higher, can realize that the wax-pattern internal heat is lost fast, shortens the wax-pattern manufacturing cycle, improves the wax-pattern quality.
The method for fast mfg of metal die provided by the invention is compared with traditional metal die, and manufacturing cycle is short, and the manufacturing cycle was looked the mould complexity about 3-7 days; The mould that can prepare any complexity; Compare with the mould that complete resin constitutes, mould structure is made of metal fully, heat conductivility is better, save material and cost, remove resinous principle fully, the thermal conductivity that the structure of metal conformal cooling pipe has also increased mould more can and mould strength, shorten the wax-pattern manufacturing cycle significantly and improve the quality of wax-pattern.Make wax-pattern to solidify by shorter time, shorten the wax-pattern manufacturing cycle greatly, and improve the wax-pattern quality.Metal conformal cooling duct had both increased the compulsory heat exchange of mould inside, had increased the structural strength of mould again.
The method for fast mfg of metal die provided by the invention, the metal die of made can be used as presses wax-pattern tool, injection mold, diel etc., and the element precision of acquisition can reach CT4-CT5.
Description of drawings
Fig. 1 is a kind of structural representation of turbo blade;
Fig. 2 is and male model and master mold constitute the structural representation of mould.
Fig. 3-the 1st, the schematic diagram of male model formwork;
Fig. 3-the 2nd, the schematic diagram of metal cooling water channel;
Fig. 3-the 3rd, the schematic diagram of shell and water channel assembly;
Fig. 3-the 4th, the schematic diagram of solidified forming mould.
The specific embodiment
The present invention is described in further detail below in conjunction with specific embodiment, and the explanation of the invention is not limited.
Metal die comprises that male model, master mold constitute among the present invention, the interior shape face of male model, master mold is made complicated surface by photocuring and is made repeatedly, use photocuring to make complicated die, die surface and the thick low-melting alloy of sidewall spraying 3-6mm use alkali corrosion to remove the outer light cured resin and can obtain the metal die shell.Use photocuring to make the conformal pipeline, advanced spraying and corroded the back to obtain metal conformal pipeline.Metal die shell and metal conformal cooling pipe by after the design and assembly, with metal powder be packed in the mould of assembling after the low melting point solder of thawing mixes by a certain percentage, can obtain metal die behind the cooling curing.
A kind of metal die method for fast mfg towards turbo blade may further comprise the steps:
1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, after mould structure is taken out shell 3~5mm and removed a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; Inner surface and the thick low-melting alloy of madial wall spraying 3~6mm at the resin mould spare of manufacturing obtain the metal die shell with resin corrosion back again;
2) design its conformal cooling pipe according to mould structure, use the photocuring rapid prototyping method to make the conformal cooling pipe resin piece then; At the thick low-melting alloy of the outer wall spraying 2~4mm of prepared cooling pipe resin piece, again resin corrosion back is obtained metal shape cooling pipe;
3) will obtain the assembling shell after metal die shell and the assembling of metal shape cooling pipe, in assembling shell cavity, fill the low melting point solder of thawing and the composite material of metal powder, fill up the assembling shell and evenly be coated with the surface flat; Cooling curing obtains metal die under normal temperature condition then, and is again that its surface finish is smooth.
The interior shape face of described male model, master mold is made repeatedly by the shape face of resin die;
Assemble again after male model and master mold prepared metal pattern respectively, form a complete metal die.
Concrete, according to design of part designing mould structure, die structure size precision and surface quality are higher than the precision quality of target wax-pattern, keep appearance and size indeformable simultaneously in slurry perfusion.The mould three-dimensional structure of design is carried out body take out shell 3-5mm, and remove a non-mating surface.
Adopt this resin mould spare of photocuring rapid prototyping fabrication techniques, at male model and master mold inner surface and sidewall thereof by the thick low-melting alloy of arc spraying technology spraying 3-6mm, use the alkali corrosion method to remove the outer field light-cured resin of mould, obtain the metal die shell.
Use the conformal cooling pipe of photocuring rapid prototyping technology mfg. moulding die, at the thick low-melting alloy of the outer wall spraying 2-4mm of conformal pipeline, use the alkali corrosion method to remove internal resin, obtain the metal conformal cooling pipe, metal conformal cooling pipe and metal die shell are pressed the project organization assembling.
Concrete, described photocuring rapid prototyping method comprises: at first use delamination software (lift height is 0.1mm) that the resin die that designs is converted into plurality of thin layer plane graph data and be input to (such as " the permanent logical intelligence machine Co., Ltd in Shaanxi " production SPS450B type photocureable rapid shaping machine) in the photocureable rapid shaping machine; During photocuring rapid prototyping, use laser instrument successively to scan the liquid resin liquid level, the resin after successively solidifying constitutes needed resin die; Normal temperature following hardening time is 6-24h, is 3-12h 30-35 ℃ of condition following hardening time.
The light-cured resin that is adopted in the described photocuring rapid prototyping method is the Somos14120 type photosensitive resin, and 30 ℃ of following viscosity are about 240cps when liquid, density 1.1~1.2g/cm
3, photocuring after-drawing intensity 45.4~45.7MPa, elastic modelling quantity 2460~2500MPa, shore hardness are that D is about 81.
Described spraying is electric arc spraying, and the low temperature gold that closes that spraying is used is the ZnAl alloy, and spray voltage is 28~30V in the spraying process, and electric current is 50~80A, air pressure 0.4-0.5MPa, sweep speed 8m/min, spray distance 200mm.The fusing point of described low melting point alloy is lower than 200 ℃.
And described resin corrosion process is that resin is corroded 1~4h in chemical corrosion liquid, and light-cured resin is removed; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide.
After obtaining the metal die shell, the low melting point solder is heated to 180-220 ℃ of thawing, with the mould inside that is filled into assembling after metal powder evenly mixes by a certain percentage, die surface evenly is coated with flat.Normal temperature condition bed die cooling curing, die surface use sand papering can obtain metal die.
During the preparation filling paste, need to guarantee that the low melting point solder is in melting state, do not influence simultaneously the structure of metal die, therefore in order to reach the filling effect that well flows, guarantee that the material filling is closely knit, reply selects fusing point to be lower than the solder of the fusing point (being about 200 ℃) of spraying alloy, and solder and the metal powder that melts is mixed with form slurry, can select to use the auxiliary grouting of vibratory equipment in filling paste.
Described composite material is filled under 180~220 ℃ of temperature, and the fusing point of low melting point solder is lower than 200 ℃; Described metal powder is copper powder, aluminium powder or iron powder; When the filling of mixed slurry, use the auxiliary grouting of vibratory equipment.The melting temperature of described low melting point solder will be lower than the melting temperature of the low-melting alloy that is sprayed, and the mass ratio of metal powder is 30~60% in the composite material.
The metal die that the combination of the present invention by technology such as photocuring rapid prototyping, electric arc spraying, resin corrosion obtains, in 5-8 days, make metal die, its precision can reach the CT4 grade, and the mould thermal conductivity is good, intensity is higher, guarantees can evenly cool off fast when wax-pattern is shaped.This method is short with respect to the conventional art manufacturing cycle, saves material and cost, can make complicated metal die fast.Described die size precision and surface quality are higher than the precision quality of target prepared product wax-pattern, keep assembling die shape size constancy shape simultaneously in the composite material perfusion; The described metal die rear surface of being polished is smooth, no bubble or projection.
Referring to Fig. 3-1~Fig. 3-4, provide a specific embodiment below, make certain model turbo blade mould (as shown in Figure 1) according to above-mentioned flow process, specifically comprise following operation:
1, formwork design and photocuring manufacturing.Divide mould according to blade construction, design feature die structure is taken out shell 2.5mm with the feature die structure, removes upper surface and obtains blade mold feature die structure chart.Use uv equipment to make photocuring formwork structure, obtain the resin piece of mould feature die according to every layer of 0.1mm.Resin piece is removed resin through the electric arc spraying post-etching, can obtain the metal shell, shown in Fig. 3-1.
2, make the metal cooling water channel.The design cooling water channel structure, photocuring is made the cooling water channel structure resin piece.The resin water channel is removed resin through the electric arc spraying post-etching can obtain the metal cooling water channel, shown in Fig. 3-2.
3, mould skeleton assembling.With metal cooling water channel and the assembling of metal die shell, the mould skeleton structure after obtaining assembling is shown in Fig. 3-3.
4, solder is filled solidified forming.The low melting point solder is heated to 200 degrees centigrade, is packed in the mould skeleton structure, the polishing of curing to be cooled rear surface can obtain metal pattern up and down, as shown in Figure 3-4.
5, mould assembling.The assembling of metal pattern up and down that obtains can be obtained final turbo blade mould, as shown in Figure 2.
Claims (10)
1. the metal die method for fast mfg towards turbo blade is characterized in that, may further comprise the steps:
1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, after mould structure is taken out shell 3~5mm and removed a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; Inner surface and the thick low-melting alloy of madial wall spraying 3~6mm at the resin mould spare of manufacturing obtain the metal die shell with resin corrosion back again;
2) design its conformal cooling pipe according to mould structure, use the photocuring rapid prototyping method to make the conformal cooling pipe resin piece then; At the thick low-melting alloy of the outer wall spraying 2~4mm of prepared cooling pipe resin piece, again resin corrosion back is obtained metal shape cooling pipe;
3) will obtain the assembling shell after metal die shell and the assembling of metal shape cooling pipe, in assembling shell cavity, fill the low melting point solder of thawing and the composite material of metal powder, fill up the assembling shell and evenly be coated with the surface flat; Cooling curing obtains metal die under normal temperature condition then, and is again that its surface finish is smooth.
2. the metal die method for fast mfg towards turbo blade as claimed in claim 1 is characterized in that, the interior shape face of described male model, master mold is made repeatedly by the shape face of resin die;
Assemble again after male model and master mold prepared metal pattern respectively, form a complete metal die.
3. the metal die method for fast mfg towards turbo blade as claimed in claim 1, it is characterized in that described photocuring rapid prototyping method comprises: at first use delamination software that the resin die that designs is converted into plurality of thin layer plane graph data and be input in the photocureable rapid shaping machine; During photocuring rapid prototyping, use laser instrument successively to scan the liquid resin liquid level, the resin after successively solidifying constitutes needed resin die; Normal temperature following hardening time is 6-24h, is 3-12h 30-35 ℃ of condition following hardening time.
4. the metal die method for fast mfg towards turbo blade as claimed in claim 3 is characterized in that, the light-cured resin that is adopted in the described photocuring rapid prototyping method, and 30 ℃ of following viscosity are about 240cps when liquid, density 1.1~1.2g/cm
3, photocuring after-drawing intensity 45.4~45.7MPa, elastic modelling quantity 2460~2500MPa, shore hardness are that D is about 81.
5. the metal die method for fast mfg towards turbo blade as claimed in claim 1, it is characterized in that, described spraying is electric arc spraying, the low temperature gold that closes that spraying is used is the ZnAl alloy, spray voltage is 28~30V in the spraying process, and electric current is 50~80A, air pressure 0.4-0.5MPa, sweep speed 8m/min, spray distance 200mm.
6. the metal die method for fast mfg towards turbo blade as claimed in claim 1 is characterized in that the fusing point of described low melting point alloy is lower than 200 ℃.
7. the method for fast mfg of metal die as claimed in claim 1 is characterized in that, described resin corrosion process is that resin is corroded 1~4h in chemical corrosion liquid, and light-cured resin is removed; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide.
8. the metal die method for fast mfg towards turbo blade as claimed in claim 1, it is characterized in that, the melting temperature of described low melting point solder will be lower than the melting temperature of the low-melting alloy that is sprayed, and the mass ratio of metal powder is 30~60% in the composite material.
9. the metal die method for fast mfg towards turbo blade as claimed in claim 1 is characterized in that described composite material is filled under 180~220 ℃ of temperature, the fusing point of low melting point solder is lower than 200 ℃; Described metal powder is copper powder, aluminium powder or iron powder; When the filling of mixed slurry, use the auxiliary grouting of vibratory equipment.
10. the metal die method for fast mfg towards turbo blade as claimed in claim 1, it is characterized in that, described die size precision and surface quality are higher than the precision quality of target prepared product wax-pattern, keep assembling die shape size constancy shape simultaneously in the composite material perfusion; The described metal die rear surface of being polished is smooth, no bubble or projection.
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CN103464690A (en) * | 2013-08-26 | 2013-12-25 | 西安交通大学 | Manufacturing method of ceramic mold of monocrystal turbine blade |
CN104416120A (en) * | 2013-08-20 | 2015-03-18 | 于彦奇 | 3D-printing sand core moulding method of large-scale hydraulic turbine blade |
CN104493081A (en) * | 2014-12-09 | 2015-04-08 | 南京航空航天大学 | Wax injection mold for investment casting of hollow turbine blades and method for rapidly manufacturing wax injection mold |
CN104907492A (en) * | 2015-05-07 | 2015-09-16 | 西安交通大学 | Making method of surface double-walled hollow turbine blade |
CN105599178A (en) * | 2016-01-11 | 2016-05-25 | 西安交通大学 | Light curing injection mold cores and manufacturing method thereof |
CN106278335A (en) * | 2016-08-05 | 2017-01-04 | 西安交通大学 | A kind of manufacture method of fiber alignment toughening ceramic based composites turbo blade |
CN107199311A (en) * | 2017-06-08 | 2017-09-26 | 西安工业大学 | A kind of combination is towards turbo blade rapid shaping and the molten mistake fusible pattern method of model casting |
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CN108746510A (en) * | 2018-05-15 | 2018-11-06 | 北京隆源自动成型系统有限公司 | Mould manufacturing method with conformal cooling channel |
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CN104416120A (en) * | 2013-08-20 | 2015-03-18 | 于彦奇 | 3D-printing sand core moulding method of large-scale hydraulic turbine blade |
CN104416120B (en) * | 2013-08-20 | 2016-05-25 | 于彦奇 | The 3D of blade of large-sized water turbine prints core formative method |
CN103464690A (en) * | 2013-08-26 | 2013-12-25 | 西安交通大学 | Manufacturing method of ceramic mold of monocrystal turbine blade |
CN104493081A (en) * | 2014-12-09 | 2015-04-08 | 南京航空航天大学 | Wax injection mold for investment casting of hollow turbine blades and method for rapidly manufacturing wax injection mold |
CN104907492A (en) * | 2015-05-07 | 2015-09-16 | 西安交通大学 | Making method of surface double-walled hollow turbine blade |
CN105599178A (en) * | 2016-01-11 | 2016-05-25 | 西安交通大学 | Light curing injection mold cores and manufacturing method thereof |
CN106278335B (en) * | 2016-08-05 | 2019-02-05 | 西安交通大学 | A kind of manufacturing method of fiber alignment toughening ceramic based composites turbo blade |
CN106278335A (en) * | 2016-08-05 | 2017-01-04 | 西安交通大学 | A kind of manufacture method of fiber alignment toughening ceramic based composites turbo blade |
CN107199311A (en) * | 2017-06-08 | 2017-09-26 | 西安工业大学 | A kind of combination is towards turbo blade rapid shaping and the molten mistake fusible pattern method of model casting |
CN107755637A (en) * | 2017-09-18 | 2018-03-06 | 东方电气集团东方汽轮机有限公司 | A kind of method for eliminating directional solidification castings defect |
CN108746510A (en) * | 2018-05-15 | 2018-11-06 | 北京隆源自动成型系统有限公司 | Mould manufacturing method with conformal cooling channel |
CN109458901A (en) * | 2018-12-07 | 2019-03-12 | 中国航发南方工业有限公司 | A kind of blade subsidiary pedestal manufacturing device |
CN109458901B (en) * | 2018-12-07 | 2020-05-19 | 中国航发南方工业有限公司 | Manufacturing device for auxiliary measuring base of blade |
CN112059259A (en) * | 2020-09-18 | 2020-12-11 | 中国航发贵州黎阳航空动力有限公司 | Machining method and machining clamp for cantilever type blade ring |
CN112059259B (en) * | 2020-09-18 | 2022-09-02 | 中国航发贵州黎阳航空动力有限公司 | Machining method and machining clamp for cantilever type blade ring |
CN113427317A (en) * | 2021-05-27 | 2021-09-24 | 北京精雕科技集团有限公司 | Temperature control structure of machine tool structural part and manufacturing method |
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