EP2274141A1 - Method for deburring a ceramic foundry core - Google Patents

Method for deburring a ceramic foundry core

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Publication number
EP2274141A1
EP2274141A1 EP09732323A EP09732323A EP2274141A1 EP 2274141 A1 EP2274141 A1 EP 2274141A1 EP 09732323 A EP09732323 A EP 09732323A EP 09732323 A EP09732323 A EP 09732323A EP 2274141 A1 EP2274141 A1 EP 2274141A1
Authority
EP
European Patent Office
Prior art keywords
tool
deburring
surface portion
ceramic
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09732323A
Other languages
German (de)
French (fr)
Other versions
EP2274141B1 (en
Inventor
Christian Defrocourt
Serge Prigent
Daniel Quach
Patrick Wehrer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
SNECMA SAS
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Filing date
Publication date
Application filed by SNECMA SAS filed Critical SNECMA SAS
Publication of EP2274141A1 publication Critical patent/EP2274141A1/en
Application granted granted Critical
Publication of EP2274141B1 publication Critical patent/EP2274141B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/18—Apparatus or processes for treating or working the shaped or preshaped articles for removing burr
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
    • B24B19/14—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding turbine blades, propeller blades or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B9/00—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor
    • B24B9/02—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor characterised by a special design with respect to properties of materials specific to articles to be ground
    • B24B9/06—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor characterised by a special design with respect to properties of materials specific to articles to be ground of non-metallic inorganic material, e.g. stone, ceramics, porcelain

Definitions

  • the present invention relates to the finishing of parts obtained by injection of a ceramic paste into a mold formed of the assembly of at least two parts, along a joint plane.
  • the invention relates more particularly to the elimination of burrs in the area of the joint plane of the two parts.
  • the invention relates to ceramic cores used in the manufacture of hollow turbine engine blades by the lost wax foundry technique.
  • foundry cores of a type called “ceramic” is particularly known in certain applications that require the achievement of a set of characteristics and stringent quality criteria such as resistance to high temperatures, lack of reactivity , dimensional stability and good mechanical characteristics.
  • these applications having such requirements there are known aeronautical applications and for example the foundry turbine blades for turbojet engines.
  • the refinement of foundry processes from the foundry known as equiaxed to the foundry by directed solidification or monocrystalline has further increased these requirements for cores whose use and complexity are imposed by the search for high performance for parts to obtain, as is the case for example for hollow vanes with internal cooling.
  • the complex crystalline structure sought in the dawn is not compatible with the burrs on the core. These can become detached during casting and pollute the room by creating inclusions and / or geometric defects. A burr that stays in place creates a crack in the room and therefore a breakaway. The cores must therefore be deburred.
  • a method, for deburring a ceramic casting core obtained by injection of a ceramic paste, said paste comprising a binder with a determined glass transition temperature, in a mold and having at least one a surface portion with a surplus of material forming a flash to be eliminated characterized in that it comprises the following steps: a. arranging and fixing the molded foundry core, before baking, on a support, b. place an elongated milling tool with a helical cutting edge on a tool holder, c. rotating the tool about its axis and bringing the milling tool into contact with said surface portion to be deburred, d. cooling the surface portion to be deburred so as to maintain it at a temperature below said glass transition temperature during the deburring operation.
  • the invention by deburring before firing the foundry core, it avoids the problem of dimensional variation of the core and opens the possibility of carrying out this operation by means of a controller. Automation ensures a better repeatability of deburring from one core to another. This results in a better deburring quality and a reduction in room breakage. Better kernel quality also reduces crack initiation. The result is a reduction in manufacturing cycles, which reduces costs.
  • an angle-propeller milling tool of between 20 and 70 ° and a hemispherical end is used.
  • the cut material is dragged away from the cutting area, reducing the risk of jamming.
  • the cutting parameters are,
  • the cooling is provided by diffusion of a fluid towards the surface portion to be deburred. This is for example air.
  • the method is particularly suitable for deburring ceramic cores of turbomachine blades. It makes it possible in particular to reduce the creep primers of the cast products.
  • a device for finishing ceramic cores of casting parts comprising a support for said core, a mandrel forming a tool-holder rotatable about its axis and at least one nozzle of injection of cooling fluid.
  • FIG. 1 represents the diagram of a turbomachine blade core
  • FIG. 2 represents the core of FIG. 1 at the outlet of the injection mold with the flash to be eliminated
  • FIG. 3 shows a milling cutter during deburring of the core
  • FIG. 4 shows the diagram of a cutter deburring position of a piece of ceramic material
  • FIG. 5 shows a device according to the invention.
  • FIG. 1 represents an exemplary piece consisting of a core element for a hollow turbine engine blade.
  • the envelope of this element 10 has the shape of the internal cavity of the hollow blade once it has been melted.
  • the element 10 comprises an upper portion 10A which will constitute the designated bath part of the blade. This part is separated from the central body 10B by a space which will constitute the transverse upper wall of the hollow blade.
  • This central portion 10B is extended downwardly by the foot 10D which is used for gripping and fixing the core in the shell mold in which the molten metal is cast.
  • the central portion is hollowed out with longitudinal openings 10B 'which will constitute the internal partitions defining the circuit of the cooling fluid to inside the dawn cavity.
  • the part 1OB extends laterally on one side by a part of the trailing edge 1OC finer and having openings 1OC which will constitute partitions between them channels that open along the trailing edge of the blade for evacuation coolant.
  • the core is intended after casting of the metal and its cooling to be removed to release the circulation cavity of the cooling air of the blade.
  • This piece is obtained by injection of a ceramic paste using a press.
  • the paste is obtained by mixing a binder, an organic polymer, and particles of ceramic materials.
  • the mixture is injected by means of injection presses, such as screw injection presses, into a metal injection mold.
  • This mold is formed of an assembly of at least two elements with cavity which are brought into contact with each other along a junction surface which is commonly referred to as joint plane.
  • joint plane a junction surface which is commonly referred to as joint plane.
  • the paste gradually spreads from the inlet to the volume formed by the fingerprints. However material passes and infiltrates between the surfaces of the joint plane. When demolding, this excess material forms the burrs.
  • FIG. 2 shows the appearance of the core of FIG. 1 at the outlet of the injection mold.
  • burr Bl which runs along the contour of the nucleus.
  • Another burr B2 is visible along the inner edges of the recesses 10C in the trailing edge area 1OC.
  • a burr B3 is also seen along the edges of the recesses 10B 'in the area 10B.
  • the rest of the process of manufacturing the core consists, after the injection, to unmold the core, bake it in a furnace at high temperature, then to ensure its finishing and dimensional control.
  • the purpose of the finish is to remove the burrs B1, B2, B3. They can be removed either just after the injection of the mixture, it is a deburring before cooking or after cooking it is then a deburring core in the cooked state.
  • the material is removed before firing, on the part after injection of the polymer-ceramic mixture in order to eliminate said problems related to the deformation of the part during and after firing.
  • the method of the invention defines core cutting parameters taking into account the intrinsic properties of the material thereof.
  • polyethylene glycol for example, has properties that can change in the vicinity of room temperature, in particular it tends to soften. This causes, when attacking the material forming the burr with a conventional milling, stuffing material. This material jam eventually prevents the removal of the burr.
  • a helical bur is used, that is to say with a longitudinal cutting edge in the form of a helix.
  • FIG. 3 shows the mode of application of the cutter 100 which is guided along the edge of the piece 10 comprising a burr.
  • the material constituting the burr B is cut by the cutting edge 100B in the form of a longitudinal helix. By this helical shape is avoided material jams along the mill 100. The material is removed continuously and the chips removed.
  • the inclination of the helix is defined by a helix angle ⁇ of between 20 and 70 degrees preferably between 35 and 65 degrees.
  • the diameter of the cutter suitable for this operation given the narrow spaces formed by the recesses is between 0.5 and 1 mm.
  • the end of the cutter is preferably hemispherical.
  • the material constituting the flash is maintained at a temperature below the glass transition temperature.
  • One way is to provide nozzles that expel cool air towards the end of the moving cutter.
  • the temperature is maintained between 16 and 26 ° C.
  • the tool is rotated on itself along the burr to be eliminated.
  • the cutting and feed speeds are adapted to the profile. For example they differ between the contour and the pocket of the core or the grooves at the exit of the trailing edge.
  • the illustrative cutting speed is between 5 and 25 m per minute and the feed rate is between 400 and 1800 mm per minute.
  • FIG. 4 shows the relative arrangement of the tool with respect to the part.
  • the piece 10 is fixed on a support 300 so as to make its contour accessible to a cutter 100 itself mounted on a mandrel 200 forming a tool holder.
  • the air injection nozzle 400 or any other suitable cooling fluid is directed on the surface of the portion of the workpiece to be deburred.
  • Figure 5 shows a deburring device.
  • the mandrel 200 is secured to a rotating support 210 which itself can be mounted on a milling machine, not shown, with three axes for example.
  • a fixed plate 220 serves to support the nozzle 400 via a bracket 410 adjustable in position. The plate may have several nozzles as needed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Milling Processes (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

The present invention relates to a method for deburring a ceramic foundry core (10) obtained by injecting a ceramic paste, said paste including a binder having a predetermined glass transition temperature, into a mold and having at least one surface portion with a surplus of material forming a burr (B) to be eliminated. The method is characterized in that it includes the following stages: a) disposing and attaching the molded, unfired foundry core (10) onto a mounting (300); b) placing a milling tool (100), having an elongated shape with a helically cut edge, onto a tool holder; c) causing the tool to rotate around its axis and touching the milling tool to said surface portion to be deburred; and d) freezing (400) the surface portion to be deburred such that the foundry core is maintained at a temperature lower than said glass transition temperature during the deburring operation.

Description

PROCEDE POUR EBAVURER UN NOYAU DE FONDERIE EN PROCESS FOR DENGURING A FOUNDRY CORE
MATIERE CERAMIQUECERAMIC MATERIAL
La présente invention porte sur la finition de pièces obtenues par injection d'une pâte céramique dans un moule formé de l'assemblage d'au moins deux parties, le long d'un plan de joint. L'invention se rapporte plus particulièrement à l'élimination des bavures dans la zone du plan de joint des deux parties. L'invention vise les noyaux céramiques utilisés dans la fabrication des aubes creuses de turbomachines par la technique de fonderie à la cire perdue.The present invention relates to the finishing of parts obtained by injection of a ceramic paste into a mold formed of the assembly of at least two parts, along a joint plane. The invention relates more particularly to the elimination of burrs in the area of the joint plane of the two parts. The invention relates to ceramic cores used in the manufacture of hollow turbine engine blades by the lost wax foundry technique.
L'utilisation de noyaux de fonderie d'un type dit « céramique » est notamment connue dans certaines applications qui imposent l'obtention d'un ensemble de caractéristiques et de critères sévères de qualité comme la tenue aux hautes températures, l'absence de réactivité, la stabilité dimensionnelle et de bonnes caractéristiques mécaniques. Parmi ces applications présentant de telles exigences, on connaît les applications aéronautiques et par exemple l'obtention en fonderie d'aubes de turbine pour turboréacteurs. Le perfectionnement des procédés de fonderie évoluant de la fonderie connue sous le nom équiaxe à la fonderie par solidification dirigée ou monocristalline a encore accru ces exigences concernant les noyaux dont l'utilisation et la complexité sont imposées par la recherche des hautes performances pour les pièces à obtenir, comme c'est le cas par exemple pour les aubes creuses à refroidissement interne.The use of foundry cores of a type called "ceramic" is particularly known in certain applications that require the achievement of a set of characteristics and stringent quality criteria such as resistance to high temperatures, lack of reactivity , dimensional stability and good mechanical characteristics. Among these applications having such requirements, there are known aeronautical applications and for example the foundry turbine blades for turbojet engines. The refinement of foundry processes from the foundry known as equiaxed to the foundry by directed solidification or monocrystalline has further increased these requirements for cores whose use and complexity are imposed by the search for high performance for parts to obtain, as is the case for example for hollow vanes with internal cooling.
La structure cristalline complexe recherchée dans l'aube n'est pas compatible avec les bavures sur le noyau. Celles-ci peuvent se détacher lors de la coulée et venir polluer la pièce en créant des inclusions et/ou des défauts géométriques. Une bavure qui reste en place crée une fissure dans la pièce et par conséquent une amorce de rupture. Les noyaux doivent donc être ébavurés.The complex crystalline structure sought in the dawn is not compatible with the burrs on the core. These can become detached during casting and pollute the room by creating inclusions and / or geometric defects. A burr that stays in place creates a crack in the room and therefore a breakaway. The cores must therefore be deburred.
Cette opération est classiquement réalisée manuellement après la cuisson. Cependant l'ébavurage manuel des noyaux fins et complexes comme par exemple les noyaux d'aubes mobiles des étages à haute pression HP ou bien les distributeurs fixes HP, est de plus en plus difficile à réaliser de manière précise et répétable. En effet, il faut être capable de réaliser en série ces opérations de haute précision. De plus ces opérations répétées sur noyaux peuvent engendrer chez les opérateurs des troubles musculo- squelettiques (TMS) dommageables pour leur santé. L'ébavurage manuel présente le risque de générer des taux élevés de rebuts avec des défauts tels que les suivants : amorces de criques, casse de noyaux lors de la manutention, manque de répétitivité, écaillage du noyau entraînant des inclusions dans les pièces de métal.This operation is conventionally carried out manually after cooking. However manual deburring of fine and complex cores such as for example the moving blade cores of HP high pressure stages or the HP fixed distributors, is increasingly difficult to achieve accurately and repeatable. Indeed, one must be able to perform these high-precision operations in series. Moreover these repeated operations on nuclei can generate in the operators of musculoskeletal disorders (TMS) damaging for their health. Manual deburring has the risk of generating high levels of rejects with defects such as: crack initiation, kernel breakage during handling, lack of repeatability, kernel spalling resulting in inclusions in metal parts.
On a cherché à automatiser le procédé d'ébavurage de la pièce après cuisson. Cependant les résultats ne sont pas satisfaisants car la déformation des pièces est mal connue en raison du retrait après cuisson. Ce retrait rend l'ébavurage par usinage très délicat et pouvant difficilement être automatisé.We tried to automate the deburring process of the room after cooking. However the results are not satisfactory because the deformation of the parts is poorly known because of the shrinkage after cooking. This removal makes deburring by machining very delicate and difficult to be automated.
On résout ce problème avec un procédé, selon l'invention, pour ébavurer un noyau de fonderie en matière céramique obtenue par injection d'une pâte céramique, ladite pâte comprenant un liant de température de transition vitreuse déterminée, dans un moule et présentant au moins une portion de surface avec un surplus de matière formant une bavure à éliminer, caractérisé par le fait qu'il comprend les étapes suivantes : a. disposer et fixer le noyau de fonderie moulé, avant cuisson, sur un support, b. placer un outil de fraisage de forme allongée avec un bord de coupe en hélice sur un porte-outil, c. entraîner en rotation l'outil autour de son axe et mettre en contact l'outil de fraisage avec ladite portion de surface à ébavurer, d. refroidir la portion de surface à ébavurer de manière à la maintenir à une température inférieure à ladite température de transition vitreuse pendant l'opération d'ébavurage.This problem is solved by a method, according to the invention, for deburring a ceramic casting core obtained by injection of a ceramic paste, said paste comprising a binder with a determined glass transition temperature, in a mold and having at least one a surface portion with a surplus of material forming a flash to be eliminated, characterized in that it comprises the following steps: a. arranging and fixing the molded foundry core, before baking, on a support, b. place an elongated milling tool with a helical cutting edge on a tool holder, c. rotating the tool about its axis and bringing the milling tool into contact with said surface portion to be deburred, d. cooling the surface portion to be deburred so as to maintain it at a temperature below said glass transition temperature during the deburring operation.
Grâce à l'invention, en procédant à l'ébavurage avant cuisson du noyau de fonderie, on évite le problème de la variation dimensionnelle du noyau et on ouvre la possibilité de procéder à cette opération au moyen d'un automate. Par l'automatisation on assure une meilleure répétitivité de l'ébavurage d'un noyau à l'autre. Il s'ensuit une meilleure qualité d'ébavurage et une diminution de la casse de pièce. Une meilleure qualité du noyau permet aussi de réduire les amorces de criques. Il s'ensuit une diminution des cycles de fabrication d'où une réduction des coûts.Thanks to the invention, by deburring before firing the foundry core, it avoids the problem of dimensional variation of the core and opens the possibility of carrying out this operation by means of a controller. Automation ensures a better repeatability of deburring from one core to another. This results in a better deburring quality and a reduction in room breakage. Better kernel quality also reduces crack initiation. The result is a reduction in manufacturing cycles, which reduces costs.
On utilise avantageusement un outil de fraisage à hélice d'angle compris entre 20 et 70° et à bout hémisphérique. De cette façon on entraîne et on éloigne la matière coupée de la zone de coupe en réduisant les risques de bourrage. Plus particulièrement les paramètres de coupe sont,Advantageously, an angle-propeller milling tool of between 20 and 70 ° and a hemispherical end is used. In this way, the cut material is dragged away from the cutting area, reducing the risk of jamming. More particularly the cutting parameters are,
- une vitesse de coupe comprise entre 5 et 30 m/min,a cutting speed of between 5 and 30 m / min,
- une vitesse d'avance de l'outil comprise entre 300 et 2000 mm/min, et - une vitesse de rotation de l'outil comprise entre 2000 et 15000 tr/min.a tool feed speed of between 300 and 2000 mm / min, and a tool rotation speed of between 2000 and 15000 rpm.
Conformément à une autre caractéristique, le refroidissement est assuré par diffusion d'un fluide en direction de la portion de surface à ébavurer. Il s'agit par exemple d'air.According to another characteristic, the cooling is provided by diffusion of a fluid towards the surface portion to be deburred. This is for example air.
Le procédé convient particulièrement à l'ébavurage de noyaux céramiques d'aubes de turbomachine. Il permet notamment une diminution des amorces de criques des produits coulés.The method is particularly suitable for deburring ceramic cores of turbomachine blades. It makes it possible in particular to reduce the creep primers of the cast products.
Pour la mise en œuvre du procédé, on utilise de préférence un dispositif de finition de noyaux céramiques de pièces de fonderie comprenant un support pour ledit noyau, un mandrin formant porte-outil mobile en rotation autour de son axe et au moins une buse d'injection de fluide de refroidissement.For the implementation of the method, it is preferable to use a device for finishing ceramic cores of casting parts comprising a support for said core, a mandrel forming a tool-holder rotatable about its axis and at least one nozzle of injection of cooling fluid.
On décrit maintenant le procédé plus en détail en référence aux dessins annexés sur lesquels :The method will now be described in more detail with reference to the accompanying drawings in which:
- la figure 1 représente le schéma d'un noyau d'aube de turbomachine, - la figure 2 représente le noyau de la figure 1 en sortie du moule d'injection avec la bavure à éliminer,FIG. 1 represents the diagram of a turbomachine blade core, FIG. 2 represents the core of FIG. 1 at the outlet of the injection mold with the flash to be eliminated,
- la figure 3 montre une fraise en cours d'ébavurage du noyau,FIG. 3 shows a milling cutter during deburring of the core,
- la figure 4 représente le schéma d'une fraise en position d'ébavurage d'une pièce en matière céramique, - la figure 5 montre un dispositif conforme à l'invention.- Figure 4 shows the diagram of a cutter deburring position of a piece of ceramic material, - Figure 5 shows a device according to the invention.
La figure 1 représente un exemple de pièce constitué d'un élément de noyau pour aube creuse de turbomachine. L'enveloppe de cet élément 10 a la forme de la cavité intérieure de l'aube creuse une fois que celle-ci aura été fondue. L'élément 10 comporte une partie supérieure 10A qui constituera la partie désignée baignoire de l'aube. Cette partie est séparée du corps central 10B par un espace qui constituera la paroi supérieure transversale de l'aube creuse. Cette partie centrale 10B est prolongée vers le bas par le pied 10D qui sert à la préhension et la fixation du noyau dans le moule carapace dans lequel est coulé le métal en fusion. La partie centrale est creusée d'ouvertures longitudinales 10B' qui constitueront les cloisons internes définissant le circuit du fluide de refroidissement à l'intérieur de la cavité de l'aube. La partie 1OB se prolonge latéralement d'un côté par une partie du bord de fuite 1OC plus fine et comportant des ouvertures 1OC qui constitueront des cloisons ménageant entre elles des canaux qui débouchent le long du bord de fuite de l'aube pour l'évacuation du fluide de refroidissement. Le noyau est destiné après coulée du métal et son refroidissement à être éliminé pour libérer la cavité de circulation de l'air de refroidissement de l'aube.FIG. 1 represents an exemplary piece consisting of a core element for a hollow turbine engine blade. The envelope of this element 10 has the shape of the internal cavity of the hollow blade once it has been melted. The element 10 comprises an upper portion 10A which will constitute the designated bath part of the blade. This part is separated from the central body 10B by a space which will constitute the transverse upper wall of the hollow blade. This central portion 10B is extended downwardly by the foot 10D which is used for gripping and fixing the core in the shell mold in which the molten metal is cast. The central portion is hollowed out with longitudinal openings 10B 'which will constitute the internal partitions defining the circuit of the cooling fluid to inside the dawn cavity. The part 1OB extends laterally on one side by a part of the trailing edge 1OC finer and having openings 1OC which will constitute partitions between them channels that open along the trailing edge of the blade for evacuation coolant. The core is intended after casting of the metal and its cooling to be removed to release the circulation cavity of the cooling air of the blade.
Cette pièce, assez complexe, est obtenue par injection d'une pâte céramique à l'aide d'une presse. La pâte est obtenue par mélange d'un liant, un polymère organique, et de particules de matières céramiques. Le mélange est injecté par le moyen de presses d'injection, telles que des presses d'injection à vis, dans un moule d'injection métallique. Ce moule est formé d'un assemblage d'au moins deux éléments avec empreinte qui sont mis en contact l'un avec l'autre le long d'une surface de jonction que l'on désigne communément plan de joint. Par l'injection, la pâte se répand progressivement depuis l'orifice d'entrée dans le volume ménagé par les empreintes. Cependant de la matière passe et s'infiltre entre les surfaces du plan de joint. Au démoulage cette matière en surplus forme les bavures. On a représenté sur la figure 2, l'aspect du noyau de la figure 1 en sortie du moule d'injection. Les zones correspondant aux plans de joint des parties du moule sont prolongées d'une bavure. Par exemple, on voit la bavure Bl qui longe le contour du noyau. Une autre bavure B2 est visible le long des bords internes des évidements 10C dans la zone du bord de fuite 1OC On voit également une bavure B3 le long des bords des évidements 10B' dans la zone 10B.This piece, quite complex, is obtained by injection of a ceramic paste using a press. The paste is obtained by mixing a binder, an organic polymer, and particles of ceramic materials. The mixture is injected by means of injection presses, such as screw injection presses, into a metal injection mold. This mold is formed of an assembly of at least two elements with cavity which are brought into contact with each other along a junction surface which is commonly referred to as joint plane. By injection, the paste gradually spreads from the inlet to the volume formed by the fingerprints. However material passes and infiltrates between the surfaces of the joint plane. When demolding, this excess material forms the burrs. FIG. 2 shows the appearance of the core of FIG. 1 at the outlet of the injection mold. The areas corresponding to the joint planes of the mold parts are extended by a burr. For example, we see the burr Bl which runs along the contour of the nucleus. Another burr B2 is visible along the inner edges of the recesses 10C in the trailing edge area 1OC. A burr B3 is also seen along the edges of the recesses 10B 'in the area 10B.
La suite du procédé de fabrication du noyau consiste, après l'injection, à démouler le noyau, le cuire dans un four à haute température, puis à assurer sa finition et le contrôle dimensionnel.The rest of the process of manufacturing the core consists, after the injection, to unmold the core, bake it in a furnace at high temperature, then to ensure its finishing and dimensional control.
La finition a pour but d'enlever les bavures Bl, B2, B3. Elles peuvent être enlevées soit juste après l'injection du mélange, il s'agit d'un ébavurage avant cuisson ou bien après la cuisson il s'agit alors d'un ébavurage de noyau à l'état cuit.The purpose of the finish is to remove the burrs B1, B2, B3. They can be removed either just after the injection of the mixture, it is a deburring before cooking or after cooking it is then a deburring core in the cooked state.
L' ébavurage habituellement fait à la main peut générer de nombreux défauts tels que rapportés plus haut.Deburring usually done by hand can generate many defects as reported above.
Des essais d' ébavurage automatique au moyen d'outils de coupe tels que des fraises ont été réalisés sur des noyaux après cuisson. Ils ne donnent pas de résultat concluant en raison notamment du fait que les noyaux à l'état cuit ont de l'un à l'autre des retraits de cuisson différents. La position de l'outil ne peut de ce fait être définie avec précision de façon répétée du fait de l'usure de la fraise due à l'abrasion et à la dureté du noyau à l'état cuit. Il y aurait nécessité de contrôler finement les zones 1OA, 1OB, 1OB', 1OC, 1OC avant ébavurage.Automatic deburring tests using cutting tools such as strawberries were carried out on cores after cooking. They do not give a conclusive result because of the fact that the nuclei in the state cooked have from one to the other different cooking recesses. The position of the tool can not therefore be accurately defined repeatedly due to wear of the cutter due to abrasion and hardness of the core in the cooked state. It would be necessary to finely control zones 1OA, 1OB, 1OB ', 1OC, 1OC before deburring.
Conformément à l'invention, on enlève la matière avant cuisson, sur la pièce après injection du mélange polymère - céramique afin de supprimer lesdits problèmes liés à la déformation de la pièce pendant et après la cuisson.According to the invention, the material is removed before firing, on the part after injection of the polymer-ceramic mixture in order to eliminate said problems related to the deformation of the part during and after firing.
Le procédé de l'invention définit des paramètres de coupe du noyau tenant compte des propriétés intrinsèques du matériau de celle ci.The method of the invention defines core cutting parameters taking into account the intrinsic properties of the material thereof.
En effet le type de liant polymère que l'on mélange à la céramique, polyéthylène glycol par exemple, présente des propriétés qui peuvent changer au voisinage de la température ambiante, en particulier il a tendance à se ramollir. Cela engendre, lorsqu'on attaque la matière formant la bavure avec une fraise conventionnelle, un bourrage de matière. Ce bourrage de matière finit par empêcher l'enlèvement de la bavure.Indeed the type of polymeric binder that is mixed with the ceramic, polyethylene glycol for example, has properties that can change in the vicinity of room temperature, in particular it tends to soften. This causes, when attacking the material forming the burr with a conventional milling, stuffing material. This material jam eventually prevents the removal of the burr.
Conformément à une caractéristique de l'invention, on utilise une fraise hélicoïdale, c'est-à-dire avec un bord de coupe longitudinal en forme d'hélice.According to a characteristic of the invention, a helical bur is used, that is to say with a longitudinal cutting edge in the form of a helix.
On a représenté sur la figure 3 le mode d'application de la fraise 100 qui est guidée le long du bord de la pièce 10 comportant une bavure. La matière constituant la bavure B est entamée par le bord coupant 100B en forme d'hélice longitudinale. Par cette forme en hélice on évite les bourrages de matière le long de la fraise 100. La matière est enlevée de manière continue et les copeaux évacués.FIG. 3 shows the mode of application of the cutter 100 which is guided along the edge of the piece 10 comprising a burr. The material constituting the burr B is cut by the cutting edge 100B in the form of a longitudinal helix. By this helical shape is avoided material jams along the mill 100. The material is removed continuously and the chips removed.
L'inclinaison de l'hélice est définie par un angle d'hélice α compris entre 20 et 70 degrés de préférence entre 35 et 65 degrés.The inclination of the helix is defined by a helix angle α of between 20 and 70 degrees preferably between 35 and 65 degrees.
Le diamètre de la fraise convenant à cette opération compte tenu des espaces étroits formés par les évidements est compris entre 0,5 et 1 mm. L'extrémité de la fraise est de préférence hémisphérique.The diameter of the cutter suitable for this operation given the narrow spaces formed by the recesses is between 0.5 and 1 mm. The end of the cutter is preferably hemispherical.
Conformément à une autre caractéristique de l'invention, on maintient la matière constituant la bavure à une température inférieure à la température de transition vitreuse. Un moyen consiste à ménager des buses expulsant de l'air frais en direction de l'extrémité de la fraise en mouvement. Par exemple pour du PEG la température est maintenue entre 16 et 26°C.According to another characteristic of the invention, the material constituting the flash is maintained at a temperature below the glass transition temperature. One way is to provide nozzles that expel cool air towards the end of the moving cutter. For example for PEG the temperature is maintained between 16 and 26 ° C.
On déplace l'outil mis en rotation sur lui-même le long de la bavure à éliminer. Les vitesses de coupe et d'avance sont adaptées au profil. Par exemple elles diffèrent entre le contour et la poche du noyau ou bien les rainures en sortie du bord de fuite.The tool is rotated on itself along the burr to be eliminated. The cutting and feed speeds are adapted to the profile. For example they differ between the contour and the pocket of the core or the grooves at the exit of the trailing edge.
La vitesse de coupe à titre d'illustration est comprise entre 5 et 25 m par minute et la vitesse d'avance est comprise entre 400 et 1800 mm par minute.The illustrative cutting speed is between 5 and 25 m per minute and the feed rate is between 400 and 1800 mm per minute.
On a représenté sur la figure 4, la disposition relative de l'outil par rapport à la pièce. La pièce 10 est fixée sur un support 300 de façon à rendre son contour accessible à une fraise 100 elle-même montée sur un mandrin 200 formant porte-outil. La buse 400 d'injection d'air ou tout autre fluide de refroidissement convenable, est dirigée sur la surface de la portion de la pièce à ébavurer.FIG. 4 shows the relative arrangement of the tool with respect to the part. The piece 10 is fixed on a support 300 so as to make its contour accessible to a cutter 100 itself mounted on a mandrel 200 forming a tool holder. The air injection nozzle 400 or any other suitable cooling fluid is directed on the surface of the portion of the workpiece to be deburred.
La figure 5 montre un dispositif d'ébavurage. Le mandrin 200 est solidaire d'un support 210 rotatif qui lui-même peut être monté sur une fraiseuse non représentée, à trois axes par exemple. Une platine 220, fixe, sert de support à la buse 400 par l'intermédiaire d'une potence 410 ajustable en position. La platine est susceptible de comporter plusieurs buses selon les besoins. Figure 5 shows a deburring device. The mandrel 200 is secured to a rotating support 210 which itself can be mounted on a milling machine, not shown, with three axes for example. A fixed plate 220 serves to support the nozzle 400 via a bracket 410 adjustable in position. The plate may have several nozzles as needed.

Claims

Revendications claims
1. Procédé pour ébavurer un noyau de fonderie (10) en matière céramique obtenue par injection d'une pâte céramique, ladite pâte comprenant un liant de température de transition vitreuse déterminée, dans un moule et présentant au moins une portion de surface avec un surplus de matière formant une bavure (B) à éliminer, caractérisé par le fait qu'il comprend les étapes suivantes : a. disposer et fixer le noyau de fonderie moulé, non cuit, sur un support (300), b. placer un outil de fraisage (100) de forme allongée avec un bord de coupe en hélice sur un porte outil, c. entraîner en rotation l'outil autour de son axe et mettre en contact l'outil de fraisage avec ladite portion de surface à ébavurer d. refroidir la portion de surface à ébavurer de manière à maintenir la pièce à une température inférieure à ladite température de transition vitreuse pendant l'opération d'ébavurage.A method for deburring a ceramic casting core (10) obtained by injection of a ceramic paste, said paste comprising a binder having a determined glass transition temperature, in a mold and having at least one surface portion with a surplus of material forming a burr (B) to be eliminated, characterized in that it comprises the following steps: a. disposing and securing the uncured cast casting core on a support (300), b. placing an elongated milling tool (100) with a helical cutting edge on a tool holder, c. rotating the tool around its axis and bringing the milling tool into contact with said surface portion to be deburred d. cooling the surface portion to be deburred to maintain the workpiece at a temperature below said glass transition temperature during the deburring operation.
2. Procédé selon la revendication 1, selon lequel on utilise un outil de fraisage (100) à hélice d'angle compris entre 20 et 70° et à bout hémisphérique.2. Method according to claim 1, wherein using a milling tool (100) with a helix angle of between 20 and 70 ° and hemispherical end.
3. Procédé selon la revendication précédente, dont les paramètres de coupe sont une vitesse de coupe comprise entre 5 et 30 m/min, une vitesse d'avance de l'outil comprise entre 300 et 2000 mm/min, et une vitesse de rotation de l'outil comprise entre 2000 et 15000 tr/min.3. Method according to the preceding claim, whose cutting parameters are a cutting speed of between 5 and 30 m / min, a feed rate of the tool of between 300 and 2000 mm / min, and a rotational speed. of the tool between 2000 and 15000 rpm.
4. Procédé selon l'une des revendications précédentes dont le refroidissement est assuré par diffusion (400) de fluide en direction de la portion de surface à ébavurer.4. Method according to one of the preceding claims whose cooling is provided by diffusion (400) of fluid in the direction of the surface portion to be deburred.
5. Procédé selon la revendication précédente dont le fluide de refroidissement est de l'air.5. Method according to the preceding claim wherein the cooling fluid is air.
6. Procédé pour ébavurer un noyau céramique d'aube de turbomachine selon l'une des revendications précédentes.6. A method for deburring a turbomachine blade ceramic core according to one of the preceding claims.
7. Utilisation d'un dispositif de finition de noyaux céramiques de pièces de fonderie pour la mise en œuvre du procédé selon la revendication 1 comprenant un support de noyau de fonderie non cuit, un mandrin formant porte-outil mobile en rotation autour de son axe et une buse d'injection de fluide de refroidissement. 7. Use of a device for finishing ceramic cores of castings for the implementation of the method according to the claim 1 comprising an uncured foundry core support, a tool-forming chuck movable about its axis and a coolant injection nozzle.
EP09732323.2A 2008-04-18 2009-04-17 Method for deburring a ceramic foundry core and use of a device to perform such method Active EP2274141B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0802179A FR2930188B1 (en) 2008-04-18 2008-04-18 PROCESS FOR DAMURING A PIECE OF CERAMIC MATERIAL
PCT/EP2009/054591 WO2009127721A1 (en) 2008-04-18 2009-04-17 Method for deburring a ceramic foundry core

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US20110049748A1 (en) 2011-03-03
JP5416762B2 (en) 2014-02-12
RU2501639C2 (en) 2013-12-20
CN102056717B (en) 2012-10-24
CA2721449C (en) 2016-08-16
CA2721449A1 (en) 2009-10-22
BRPI0910569B1 (en) 2019-02-26
JP2011516318A (en) 2011-05-26
EP2274141B1 (en) 2015-06-03
RU2010146980A (en) 2012-05-27
WO2009127721A1 (en) 2009-10-22
FR2930188A1 (en) 2009-10-23
CN102056717A (en) 2011-05-11
BRPI0910569A2 (en) 2015-09-22
FR2930188B1 (en) 2013-09-20

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