CN103223466B - Rapid metal die manufacturing method for turbine blades - Google Patents

Rapid metal die manufacturing method for turbine blades Download PDF

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Publication number
CN103223466B
CN103223466B CN201310132380.XA CN201310132380A CN103223466B CN 103223466 B CN103223466 B CN 103223466B CN 201310132380 A CN201310132380 A CN 201310132380A CN 103223466 B CN103223466 B CN 103223466B
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die
metal
resin
rapid
mould
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CN201310132380.XA
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Chinese (zh)
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CN103223466A (en
Inventor
李涤尘
鲁中良
杨东升
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西安交通大学
西安瑞特快速制造工程研究有限公司
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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

A kind of rapid metal tooling method towards turbo blade

Technical field

The invention belongs to Rapid tooling field, relate to a kind of rapid metal tooling method towards turbo blade.

Background technology

Lost-wax process is a kind of method of model casting, and wax-pattern Surface coating refractory material is made shell, and can cast after at high temperature roasting after melting mould dewax obtains precision casting.The foundry goods that model casting obtains can realize near-net-shape, and Aero-Space, the exigent part of automobile equally accurate are widely used.In lost-wax process casting, wax pattern is the middle 3D shape transferring member of hot investment casting, and its quality directly determines the precision of foundry goods.Turbo blade is that engine operating environments is the most severe, and one of part that structure is the most complicated, its manufacture method is the Focal point and difficult point of industrial quarters always.Tradition hot investment casting adopts pressure wax-pattern tool batch micro operations wax pattern, but use machine-tooled method manufacture metal die to take time and effort, and especially for the part for labyrinth, manufacturing metal die needs a large amount of time and cost.

It is high that Introduction To Stereolithography has the accuracy of manufacture, can manufacture the advantage of complicated inner cavity structure.Utilize Introduction To Stereolithography to transform as intermediate state, and then quick Fabrication metal die is the effective way shortening mold cycle, reduce manufacturing cost.

Conformal cooling pipe is the structure that Injection Mold Design will be considered, use photocuring rapid prototyping technology can manufacture the conformal cooling passage of resin material, due to the thermal conductivity factor of general resin material very low (being less than 0.5W/ (m DEG C)), resin die wax pattern cooling velocity is slow, cause the wax-pattern manufacturing cycle long, the thermal deformation of wax-pattern and mould is large, and in cooling procedure, the mass defect of wax-pattern is many, directly affects hot investment casting casting quality.

Summary of the invention

The problem that the present invention solves is to provide a kind of rapid metal tooling method towards turbo blade, turbo blade metal die is obtained by the combination of the technology such as photocuring rapid prototyping, electric arc spraying, resin erosion, save die manufacturing cost, complicated metal blade mould can be manufactured fast.

The present invention is achieved through the following technical solutions:

Towards a rapid metal tooling method for turbo blade, comprise the following steps:

1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, mould structure is taken out shell 3 ~ 5mm and after removing a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; At the inner surface of manufactured resin mould part and the thick low-melting alloy of madial wall spraying 3 ~ 6mm, then metal die shell will be obtained after resin erosion;

2) according to its conformal cooling pipe of mould structure design, photocuring rapid prototyping method is then used to manufacture conformal cooling pipe resin piece; At the low-melting alloy that the outer wall spraying 2 ~ 4mm of prepared cooling pipe resin piece is thick, then metal shape cooling pipe will be obtained after resin erosion;

3) obtain assembling shell by 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 assembling shell and surface uniform be coated with flat; Then under normal temperature condition, cooling curing obtains metal die, then by smooth for its surface finish.

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 are prepared metal pattern respectively, form a complete metal die.

Described photocuring rapid prototyping method comprises: first use delamination software the resin die designed to be converted into some layer planes graph datas and be input in photocureable rapid shaping machine; During photocuring rapid prototyping, laser instrument is used successively to scan liquid resin liquid level, the resin die required for the resin successively after solidification is formed; The ambient temperature curing time is 6-24h, and under 30-35 DEG C of condition, hardening time is 3-12h.

The light-cured resin adopted in described photocuring rapid prototyping method, when liquid, at 30 DEG C, viscosity is about 240cps, density 1.1 ~ 1.2g/cm 3, photocuring after-drawing intensity 45.4 ~ 45.7MPa, elastic modelling quantity 2460 ~ 2500MPa, shore hardness is that D is about 81.

Described spraying is electric arc spraying, and the conjunction low temperature gold that spraying uses is ZnAl alloy, and in spraying process, spray voltage is 28 ~ 30V, 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 DEG C.

Described resin erosion process is that resin is corroded 1 ~ 4h in chemical corrosion liquid, is removed by light-cured resin; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide.

The melting temperature of described low melting point solder will lower than the melting temperature of sprayed low-melting alloy, and in composite material, the mass ratio of metal powder is 30 ~ 60%.

Described composite material is filled at 180 ~ 220 DEG C of temperature, and the fusing point of low melting point solder is lower than 200 DEG C; Described metal powder is copper powder, aluminium powder or iron powder; The auxiliary grouting of vibratory equipment is used when the filling of mixed slurry.

Described die size precision and surface quality, higher than the precision quality of target prepared product wax-pattern, keep assembling die boundary dimensions indeformable simultaneously when composite material perfusion; It is smooth that described metal die is polished rear surface, bubble-free or projection.

Compared with prior art, the present invention has following useful technique effect:

The method for fast mfg of metal die provided by the invention, by designing mould structure, structure is taken out shell 3-5mm and is removed non-mating surface, Stereolithography equipment is used to prepare SL resin mould part, resin piece inner surface electric arc spraying 3-6mm low-melting alloy, use alkali corrosion to remove light-cured resin and obtain metal die shell, corrode the metal conformal cooling pipe obtained and assemble with spraying after same photocuring, then fill the low melting point solder composite material of metal powder and thawing, after solidification, polishing obtains metal worm blade mold.By the metal die that the combination of the technology such as photocuring rapid prototyping, electric arc spraying, resin erosion obtains, metal die is manufactured in 5-8 days, its precision can reach CT4 grade, and mould thermal conductivity is good, intensity is higher, can evenly cool fast when ensureing that wax-pattern is shaped.

The method for fast mfg of metal die provided by the invention, use arc spraying technology can spray low-melting alloy on light-cured resin, intensity and the thermal conductivity of low-melting alloy are better.Erosion removal light-cured resin, reduces the thermal resistance of mould further.The thermal conductivity of metal powder is better, and mixing cured by these metal dusts and low melting point solder, the mixture coefficient of heat conduction obtained is higher, can realize wax-pattern internal heat and scatter and disappear fast, shortens wax-pattern manufacturing cycle, raising wax-pattern quality.

The method for fast mfg of metal die provided by the invention, compared with traditional metal die, manufacturing cycle is short, and the manufacturing cycle looks mould complexity at about 3-7 days; Mould complicated arbitrarily can be prepared; Compared with the mould formed with complete resin, mould structure is made of metal completely, heat conductivility is better, save material and cost, remove resinous principle completely, the thermal conductivity that the structure of metal conformal cooling pipe too increases mould more can and mould strength, significantly shorten wax-pattern manufacturing cycle and improve the quality of wax-pattern.Wax-pattern energy shorter time is solidified, greatly shortens the wax-pattern manufacturing cycle, and improve wax-pattern quality.Metal conformal cooling passage had both added the compulsory heat exchange of mould inside, turn increased the structural strength of mould.

The method for fast mfg of metal die provided by the invention, made metal die can be used as pressure wax-pattern tool, injection mold, diel etc., and the element precision of acquisition can reach CT4-CT5.

Accompanying drawing explanation

Fig. 1 is a kind of structural representation of turbo blade;

Fig. 2 is and the structural representation of male model and master mold formation mould.

Fig. 3-1 is the schematic diagram of male model formwork;

Fig. 3-2 is schematic diagrames of metal cooling water channel;

Fig. 3-3 is schematic diagrames of shell and water channel assembly;

Fig. 3-4 is schematic diagrames of solidified forming mould.

Detailed description of the invention

Below in conjunction with specific embodiment, the present invention is described in further detail, and the explanation of the invention is not limited.

In the present invention, metal die comprises male model, master mold is formed, the interior shape face of male model, master mold manufactures complicated surface by photocuring and repeatedly makes, photocuring is used to manufacture complicated die, die surface and sidewall spray the thick low-melting alloy of 3-6mm, use alkali corrosion to remove outer light cured resin and can obtain metal die shell.Use photocuring to manufacture conformal pipeline, after entering spraying and corrosion, obtain metal conformal pipeline.After metal die shell and metal conformal cooling pipe are pressed design and assembly, be packed in the mould of assembling after metal powder is mixed by a certain percentage with the low melting point solder of thawing, after cooling curing, can metal die be obtained.

Towards a rapid metal tooling method for turbo blade, comprise the following steps:

1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, mould structure is taken out shell 3 ~ 5mm and after removing a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; At the inner surface of manufactured resin mould part and the thick low-melting alloy of madial wall spraying 3 ~ 6mm, then metal die shell will be obtained after resin erosion;

2) according to its conformal cooling pipe of mould structure design, photocuring rapid prototyping method is then used to manufacture conformal cooling pipe resin piece; At the low-melting alloy that the outer wall spraying 2 ~ 4mm of prepared cooling pipe resin piece is thick, then metal shape cooling pipe will be obtained after resin erosion;

3) obtain assembling shell by 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 assembling shell and surface uniform be coated with flat; Then under normal temperature condition, cooling curing obtains metal die, then by smooth for its surface finish.

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 are prepared metal pattern respectively, form a complete metal die.

Concrete, according to structural design of fittings mould structure, die structure size precision and surface quality, higher than the precision quality of target wax-pattern, keep appearance and size indeformable simultaneously when slurry perfusion.The mould three-dimensional structure of design is carried out body and takes out shell 3-5mm, and remove a non-mating surface.

Adopt this resin mould part 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 alkali corrosion method to remove the outer field light-cured resin of mould, obtain metal die shell.

Use the conformal cooling pipe of photocuring rapid prototyping technology mfg. moulding die, at the low-melting alloy that the outer wall spraying 2-4mm of conformal pipeline is thick, alkali corrosion method is used to remove internal resin, obtain metal conformal cooling pipe, metal conformal cooling pipe and metal die shell are pressed project organization and assembles.

Concrete, described photocuring rapid prototyping method comprises: first use delamination software (lift height is 0.1mm) resin die designed to be converted into some layer planes graph datas and be input to (such as " Shaanxi Heng Tong intelligence machine Co., Ltd " produces SPS450B type photocureable rapid shaping machine) in photocureable rapid shaping machine; During photocuring rapid prototyping, laser instrument is used successively to scan liquid resin liquid level, the resin die required for the resin successively after solidification is formed; The ambient temperature curing time is 6-24h, and under 30-35 DEG C of condition, hardening time is 3-12h.

The light-cured resin adopted in described photocuring rapid prototyping method, be Somos14120 type photosensitive resin, when liquid, at 30 DEG C, viscosity is about 240cps, density 1.1 ~ 1.2g/cm 3, photocuring after-drawing intensity 45.4 ~ 45.7MPa, elastic modelling quantity 2460 ~ 2500MPa, shore hardness is that D is about 81.

Described spraying is electric arc spraying, and the conjunction low temperature gold that spraying uses is ZnAl alloy, and in spraying process, spray voltage is 28 ~ 30V, 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 DEG C.

And described resin erosion process resin is corroded in chemical corrosion liquid 1 ~ 4h, light-cured resin is removed; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide.

After acquisition metal die shell, by low melting point solder heat to 180-220 DEG C of thawing, with the mould inside being filled into assembling after metal powder by a certain percentage Homogeneous phase mixing, die surface is evenly coated with flat.Normal temperature condition bed die cooling curing, die surface uses sand papering to obtain metal die.

When preparing filling paste, need to ensure that low melting point solder is in melting state, do not affect the structure of metal die simultaneously, therefore in order to reach the filling effect that well flows, ensure that material is filled closely knit, reply selects fusing point lower than the solder of the fusing point (being about 200 DEG C) of spraying alloy, and the solder of thawing and metal powder are mixed with form slurry, can the auxiliary grouting of choice for use vibratory equipment when filling paste.

Described composite material is filled at 180 ~ 220 DEG C of temperature, and the fusing point of low melting point solder is lower than 200 DEG C; Described metal powder is copper powder, aluminium powder or iron powder; The auxiliary grouting of vibratory equipment is used when the filling of mixed slurry.The melting temperature of described low melting point solder will lower than the melting temperature of sprayed low-melting alloy, and in composite material, the mass ratio of metal powder is 30 ~ 60%.

The metal die that the present invention is obtained by the combination of the technology such as photocuring rapid prototyping, electric arc spraying, resin erosion, metal die is manufactured in 5-8 days, its precision can reach CT4 grade, and mould thermal conductivity is good, intensity is higher, can evenly cool fast when ensureing that wax-pattern is shaped.This method is short relative to the conventional art manufacturing cycle, saves material and cost, can manufacture complicated metal die fast.Described die size precision and surface quality, higher than the precision quality of target prepared product wax-pattern, keep assembling die boundary dimensions indeformable simultaneously when composite material perfusion; It is smooth that described metal die is polished rear surface, bubble-free or projection.

See Fig. 3-1 ~ Fig. 3-4, provide a specific embodiment below, according to above-mentioned flow manufacturing model turbo blade mould (as shown in Figure 1), specifically comprise following operation:

1, formwork design and photocuring manufacture.According to blade construction parting, design feature die structure, takes out shell 2.5mm by feature die structure, removes upper surface and obtains blade mold feature die structure chart.Use uv equipment to manufacture photocuring formwork structure according to every layer of 0.1mm, obtain the resin piece of die male master mold.Resin piece is removed resin through electric arc spraying post-etching, metal shell can be obtained, as shown in figure 3-1.

2, metal cooling water channel is manufactured.Design cooling water channel structure, photocuring manufactures cooling water channel structure resin piece.Resin water channel is removed resin through electric arc spraying post-etching and can obtain metal cooling water channel, as shown in figure 3-2.

3, mould skeleton assembling.Metal cooling water channel and metal die shell are assembled, obtains the mould skeleton structure after assembling, as shown in Fig. 3-3.

4, solidified forming filled by solder.By low melting point solder heat to 200 degrees Celsius, be packed in mould skeleton structure, solidification rear surface to be cooled polishing can obtain upper and lower metal pattern, as shown in Figure 3-4.

5, die assembly.The metal pattern up and down obtained assembling can be obtained final turbo blade mould, as shown in Figure 2.

Claims (7)

1., towards a rapid metal tooling method for turbo blade, it is characterized in that, comprise the following steps:
1) according to the structural design mould structure of target prepared product, mould structure is decomposed into male model, master mold, mould structure is taken out shell 3 ~ 5mm and after removing a non-mating surface, uses photocuring rapid prototyping method mfg. moulding die resin piece; At the inner surface of manufactured resin mould part and the thick low-melting alloy of madial wall spraying 3 ~ 6mm, then metal die shell will be obtained after resin erosion;
2) according to its conformal cooling pipe of mould structure design, photocuring rapid prototyping method is then used to manufacture conformal cooling pipe resin piece; At the low-melting alloy that the outer wall spraying 2 ~ 4mm of prepared cooling pipe resin piece is thick, then metal shape cooling pipe will be obtained after resin erosion;
3) obtain assembling shell by 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 assembling shell and surface uniform be coated with flat; Then under normal temperature condition, cooling curing obtains metal die, then by smooth for its surface finish;
Wherein, in above-mentioned steps, described spraying is electric arc spraying, and the low-temperature alloy that spraying uses is ZnAl alloy, and in spraying process, spray voltage is 28 ~ 30V, and electric current is 50 ~ 80A, air pressure 0.4-0.5MPa, sweep speed 8m/min, spray distance 200mm;
Described resin erosion process is that resin is corroded 1 ~ 4h in chemical corrosion liquid, is removed by light-cured resin; Described chemical corrosion liquid is the alcoholic solution with NaOH or potassium hydroxide;
The melting temperature of described low melting point solder will lower than the melting temperature of sprayed low-melting alloy, and in composite material, the mass ratio of metal powder is 30 ~ 60%.
2., as claimed in claim 1 towards the rapid metal tooling method of turbo blade, it 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 are prepared metal pattern respectively, form a complete metal die.
3. as claimed in claim 1 towards the rapid metal tooling method of turbo blade, it is characterized in that, described photocuring rapid prototyping method comprises: first use delamination software the resin die designed to be converted into some layer planes graph datas and be input in photocureable rapid shaping machine; During photocuring rapid prototyping, laser instrument is used successively to scan liquid resin liquid level, the resin die required for the resin successively after solidification is formed; The ambient temperature curing time is 6-24h, and under 30-35 DEG C of condition, hardening time is 3-12h.
4., as claimed in claim 3 towards the rapid metal tooling method of turbo blade, it is characterized in that, the light-cured resin adopted in described photocuring rapid prototyping method, when liquid, at 30 DEG C, viscosity is about 240cps, density 1.1 ~ 1.2g/cm 3, photocuring after-drawing intensity 45.4 ~ 45.7MPa, elastic modelling quantity 2460 ~ 2500MPa, shore hardness is that D is about 81.
5., as claimed in claim 1 towards the rapid metal tooling method of turbo blade, it is characterized in that, the fusing point of described low melting point alloy is lower than 200 DEG C.
6., as claimed in claim 1 towards the rapid metal tooling method of turbo blade, it is characterized in that, described composite material is filled at 180 ~ 220 DEG C of temperature, and the fusing point of low melting point solder is lower than 200 DEG C; Described metal powder is copper powder, aluminium powder or iron powder; The auxiliary grouting of vibratory equipment is used when the filling of mixed slurry.
7. as claimed in claim 1 towards the rapid metal tooling method of turbo blade, it is characterized in that, described die size precision and surface quality, higher than the precision quality of target prepared product wax-pattern, keep assembling die boundary dimensions indeformable simultaneously when composite material perfusion; It is smooth that described metal die is polished rear surface, bubble-free or projection.
CN201310132380.XA 2013-04-17 2013-04-17 Rapid metal die manufacturing method for turbine blades CN103223466B (en)

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CN104416120B (en) * 2013-08-20 2016-05-25 于彦奇 The 3D of blade of large-sized water turbine prints core formative method
CN103464690B (en) * 2013-08-26 2016-12-07 西安交通大学 A kind of manufacture method of ceramic mold of monocrystal turbine blade
CN104493081B (en) * 2014-12-09 2016-07-06 南京航空航天大学 Wax injection mould and method for fast mfg thereof for hollow turbine vane model casting
CN104907492B (en) * 2015-05-07 2017-03-08 西安交通大学 A kind of manufacture method towards double wall hollow turbine vane
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
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
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

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