EP3288699A1 - Procede de fabrication de modele pour fonderie a modele perdu - Google Patents
Procede de fabrication de modele pour fonderie a modele perduInfo
- Publication number
- EP3288699A1 EP3288699A1 EP16722312.2A EP16722312A EP3288699A1 EP 3288699 A1 EP3288699 A1 EP 3288699A1 EP 16722312 A EP16722312 A EP 16722312A EP 3288699 A1 EP3288699 A1 EP 3288699A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- model
- portions
- insert
- manufacturing
- blade
- 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
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 55
- 238000005495 investment casting Methods 0.000 title abstract 2
- 239000000463 material Substances 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 claims description 33
- 238000005266 casting Methods 0.000 claims description 16
- 239000000654 additive Substances 0.000 claims description 7
- 230000000996 additive effect Effects 0.000 claims description 7
- 238000002347 injection Methods 0.000 claims description 5
- 239000007924 injection Substances 0.000 claims description 5
- 238000004026 adhesive bonding Methods 0.000 claims description 4
- 238000003466 welding Methods 0.000 claims description 3
- 239000002184 metal Substances 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 9
- 238000007789 sealing Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 6
- 238000002844 melting Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 3
- 239000004926 polymethyl methacrylate Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000004873 anchoring Methods 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
- 239000003351 stiffener Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
- B22C7/023—Patterns made from expanded plastic materials
- B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
- B22C13/085—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores by investing a lost pattern
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
- B22C9/103—Multipart cores
Definitions
- the invention relates to the manufacture of lost model foundry models.
- 'lost model foundry model' or simply 'foundry model' or even 'model' is meant here a part made at least in part of a removable material, and having substantially the same shape as the part that the we are trying to manufacture.
- the material is removable means in this context (of a foundry model) that this material is likely to be removed without destroying or damaging the mold formed around the foundry model. This elimination can be made chemically (baths ..), and / or thermal, or other.
- the disposable material may simply be a low temperature fusible material.
- low temperature fuse herein means fuse at a temperature below 500 ° C, and preferably below 100 ° C.
- a model may include one or more inserts, which are parts incorporated into the model either to allow the manufacture thereof or to be part of the part that is to be manufactured.
- the lost-model foundry is a known method usually comprising the following steps: foundry models are made; around these models a shell mold is formed; the models are then eliminated (with the exception of any inserts) by heating the mold: the models melt and / or burn (with the exception of any inserts); the material that constitutes them is then removed from the mold. The shell mold is then used to make parts by foundry.
- the invention more specifically relates to the manufacture of lost model foundry models comprising an insert.
- Such models are used either to manufacture parts which themselves include an insert, or to manufacture hollow parts: in the latter case, the insert of the foundry model is a core, which serves to develop the hollow part of the room during the casting of the molten metal, and is then removed after cooling the metal mass.
- the object of the invention is therefore to provide a method of manufacturing foundry models, for the manufacture of foundry models with an insert, faster and cheaper than the traditional method described above.
- the insert (s) may include in particular a core, intended to be removed after the casting step during the lost pattern foundry. This or these cores may be in particular one or ceramic core (s).
- One or more insert (s) can also be permanent inserts, intended to be integrated into the room for example to strengthen it mechanically. The meeting of the said at least two portions forms the model. Therefore, the shape of the model is the union of shapes (or volumes) of the different portions.
- the foundry model is made by assembling several model portions, the method below provides greater flexibility compared to the traditional mold injection-molding process.
- the different portions of the model are easier to manufacture, each, than the model itself; in particular, because these portions do not have an insert.
- the step S1B) of manufacturing one or more of the model portions can be made by manufacturing one or more of said portions of the model by an additive method. It can also be done by injection. It can also be made by any other method suitable for the manufacture of a model portion.
- step S1A) of supplying the insert (s) can be made by manufacturing the insert (s) by an additive process, by injection or by any other another suitable method.
- step S2 The realization of the model by assembling its portions around the insert or inserts in step S2), however, requires some precautions.
- step S2 means that the connection areas between the model portions and the insert and / or between the model portions between them do not let any foreign body pass, as well as the useful parts of the rest of the model. It is for this purpose that in step S2, "said at least two model portions are assembled in a sealed manner around at least a portion of said at least one insert". In some embodiments, the at least two model portions are assembled in a sealed manner around the entire insert.
- the insert (s) do not exceed (not) outside the model: they are strictly contained inside thereof and sealed from the outside space to the model.
- the model portions are tightly assembled around only a portion of the insert.
- the inserts may exceed the outside of the model; the parts of the inserts that protrude are called appendices.
- it is possible to carry out a waterproofing of the at least two model portions for example using a small heating iron.
- These appendages or inserts exceeding the model portion or portions may be useful in the molding process, in particular for anchoring the insert in the shell, for example to respect the wall thicknesses on the final part or for the maintenance and dimensional control of the hollow cavity.
- the melting properties of this material can be used locally to seal the foundry model during the manufacturing step S2).
- any other method adapted to make this model waterproof during step S2) can be used (in particular by adding sealing resin or the like), in particular if the model portions are not made of hot melt material.
- step S2) of the method comprises two sub-steps:
- the method is applicable in particular to the manufacture of foundry models having an aerodynamic profile.
- the method is applicable in particular to the manufacture of foundry models comprising a blade.
- step S1B in a preferred mode of implementation of the method, exactly two portions of the model are provided, a portion of intrados including the portion of the blade located on the intrados side, and an extrados portion including the portion of the blade located on the extrados side.
- the invention also relates to a method for manufacturing a lost-model foundry part, in which a model is manufactured by the method described above.
- the invention also relates to a model for a lost model foundry, comprising at least two integrally unmaintained portions and at least one insert, said at least two portions being attached to each other in a sealed manner around at least a portion of said at least one minus an insert; said at least two portions being made of removable material; and said at least one insert having a melting temperature above 1300 ° C.
- the insert is therefore made of a material having a melting point higher than the melting temperature of the metal.
- FIG. 2 is a schematic perspective view of a cluster of blade models obtained during the implementation of the method presented in FIG. 1;
- FIG. 3 is a schematic perspective view of a blade model used during the implementation of the method presented in FIG. 1;
- FIG. 4 is a schematic exploded perspective view of the blade model shown in Figure 3;
- FIG. 5 is a schematic sectional view of the blade model presented in FIG. 3
- FIG. 6 is a schematic perspective view of the blade model section shown in FIG. 5;
- FIG. 7 is a schematic perspective view of a model comprising an insert having appendages.
- the blade manufacturing process shown in FIG. 1 is a lost pattern casting process.
- the method is presented in the context of the manufacture of a cluster of twelve turbomachine blades.
- the method comprises seven steps S1 to S7.
- the steps S1 and S2 are identical for each of the twelve blades. They will therefore be described as part of a (unique) dawn; In practice, it is necessary to carry out these steps for each of the twelve blades.
- SI Making the core and portions of the model.
- This step S1 comprises two operations to be performed in parallel: during a step S1A, a core (10) is manufactured;
- One method is to create the numerical definitions of the portions of the model from the numeric definition of the part.
- the piece is divided into several portions.
- the part comprises a blade (as is the case in the example presented)
- the part can be divided into an extrados portion 12 including the portion of the blade located on the extrados side, and a portion of intrados 14 including the portion of the blade located on the side of the intrados.
- the model 16 is then the meeting of two portions, a portion of intrados 12 and an extrados portion 14, which correspond to the portions of the blade located respectively on the side of the intrados and the side of the extrados (FIG. .3).
- the model portions may be defined with junction areas having shape complementarities (cones, steps, etc.). These shape complementarities serve, during the assembly of the model portions, to ensure the relative good positioning of the different portions of the model, which is important to ensure that the model obtained has the shape as close as possible to that specified by the model. numerical definition of the piece.
- the model portions may furthermore be defined with recesses and / or housings, intended to cooperate with corresponding parts of the core, so that the core is precisely held in position by the blade portions inside the dawn pattern.
- one or more of the model portions can be manufactured by an additive method.
- Various methods of rapid prototyping can be used.
- the core 10 may also be produced by an additive process, or in a conventional manner by injection / baking.
- the materials and manufacturing processes respectively of the model portions and the core shall be selected so that:
- model portions can be removed by heating or other without leaving unwanted residues such as soot or traces carbonaceous (in step S5 described below);
- the core can withstand the thermal stresses applied during the casting of the blade cluster and can be removed by chemical bath without leaving unwanted residues (in step S6 described below).
- the removal of the model portions can be chemical, hypercritical debinding, etc.
- the two model portions 12 and 14 are assembled around the core 10 (as an insert), which makes it possible to constitute a blade model 16.
- the portions are then fixed. of model 12 and 14 to one another by gluing. While remaining within the scope of the invention, other methods of attachment can be used, such as welding, mechanical assembly for example by interlocking and / or screwing, etc.
- this step S2 it manufactures a cluster of 20 wax models (Fig.2), also called the e Grap not permanent.
- This cluster 20 is used to manufacture a shell mold by forming hollow volumes in the shell mold, in a manner known per se.
- the cluster 20 is manufactured by assembling the blade models 16 made in step S2 using prefabricated auxiliary elements 22.
- auxiliary elements 22 serve to form the technical parts of the shell mold, including metal feed and discharge channels, heat shields, etc. They comprise in particular two parallel disks 24, each of these disks having the shape of a plate pierced with holes through which the blade models 16 pass.
- the dawn patterns 16 are all identical to each other. They are arranged in a circle axisymmetrically about an axis X, said casting axis.
- the X axis is disposed in the vertical direction during the foundry operation, when molten metal is poured into the shell mold (operation discussed in more detail below).
- the blade models 16 will be used to develop molding cavities for blade molding; the auxiliary elements 22 will be used to develop including a casting bucket, feed channels, stiffeners and selectors.
- step S4 the shell mold is made by immersing the non-permanent bundle 20 in a slip from which the shell is formed (this step as well as the subsequent steps S5 to S7 are described in more detail in WO2014 / 049 223).
- the blade models are eliminated by heating the shell mold in which the non-permanent cluster is located. Under the effect of heat, the dawn patterns melt and / or burn, eliminating them and releasing the inner volume of the shell mold.
- the cluster of castings - that is, the blade cluster - is then formed in the shell mold by casting molten metal therein.
- a sixth step S6 after the cooling and solidification of the metal in the shell mold, the blade cores are removed by dipping in a basic chemical bath, and the blade cluster is unchecked from the shell mold.
- each of the blades is separated from the rest of the cluster and finished by machining processes and / or surface treatments.
- the invention relates more particularly to steps S1 and S2, that is to say the manufacture of blade models 16. An example of implementation of these steps is illustrated by Figures 3 to 6.
- the blade model 16 is a wax model of a blade having a blade 30 and a foot 32.
- Figure 3 shows the blade model 16 obtained by assembling three components namely the extrados portion 12, the core 10 and the intrados portion 14 (Fig.4).
- Figures 5 and 6 show a section of the model 16 in a plane P perpendicular to its longitudinal axis.
- the dawn that the dawn model 16 is used to make is a hollow dawn. Also, for the manufacture of this one by lost model foundry, it is necessary to use a nucleus - in this case the nucleus 10.
- the shape of the core 10 delimits the interior volume of the dawn that one seeks to keep empty, that is to say the interior volume of the dawn which must not be filled with metal during the foundry.
- the model portions 12 and 14 are provided with frustoconical projections 11, and the core 10 is provided with corresponding holes 11 of frustoconical shape, which allow a precise relative position of the core 10 relative to the model portions 12 and 14.
- the core 10 is made separately ceramic in step S1A, in a manner known per se (for example by molding in a core box, or additive manufacturing for example by sintering powder). It consists mainly of silica.
- step S6 Its material is selected so that its melting point is above 1300 ° C. Because of this, the core does not melt during the step S5 casting of the blade cluster. Conversely, this material is selected so that it can be removed by chemical solvents in step S6.
- the model portions 12 and 14 are manufactured separately (step S1B). They are made of removable material: in this case, fuse material at low temperature. They can for example be manufactured in rapid prototyping, by wax filament deposition or by powder sintering. They can be made for example of PMMA (polymethylmethacrylate) or other organic polymers. These materials can be removed by being brought to a temperature of the order of 1000 ° C in a firing oven, in step S5 before the casting of the metal.
- removable material in this case, fuse material at low temperature. They can for example be manufactured in rapid prototyping, by wax filament deposition or by powder sintering. They can be made for example of PMMA (polymethylmethacrylate) or other organic polymers. These materials can be removed by being brought to a temperature of the order of 1000 ° C in a firing oven, in step S5 before the casting of the metal.
- the shape of the model portions 12 and 14 is such that the union of their volumes substantially corresponds to the volume of the blade that is to be manufactured.
- the portions 12 and 14 are in contact at two contact surfaces: an upstream contact surface 15 and a downstream contact surface 17. These surfaces are defined in such a way that the union of the core 10, portions 12 and 14 easily and without difficulty related to undercuts or other.
- step S21 a thin layer of adhesive is deposited on the contact surfaces 15 and 17; the portions 12 and 14 are glued to each other, the core 10 being disposed therebetween.
- step S22 the model 16 is sealed by sealing at each of the contact surfaces (15, 17) between the different model portions.
- This seal is obtained by slightly melting the wax or the PMMA locally so as to bond portions 12 and 14 to one another.
- the slip does not penetrate inside the model 16 (that is to say between the portions 12 and 14, and in contact core 10).
- the insert core was entirely contained in the model 16.
- portions of the core 10 may also protrude outside the model 16, as illustrated by the appendices 13 of the figure. 7.
- the appendages 13 are provided for anchoring the core 10 in the shell mold subsequently made.
- an expansion zone 18 may be provided so that there remains a clearance between the core 10 and the shell mold subsequently formed. Indeed, there may be a differential thermal expansion between the core 10 and the shell mold during the baking cycle of the shell mold containing the core and then the casting cycle of the parts, here blades. The expansion zone 18 and the resulting clearance ensure that the core 10 does not break under the effect of the differential expansion.
- the model produced by the process according to the invention may be that of a part to be manufactured; but it may possibly include additional parts that are not part of the part to be manufactured and are eliminated during the finishing step (S7). Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1553937A FR3035604B1 (fr) | 2015-04-30 | 2015-04-30 | Procede de fabrication de modele pour fonderie a modele perdu |
PCT/FR2016/050980 WO2016174344A1 (fr) | 2015-04-30 | 2016-04-26 | Procede de fabrication de modele pour fonderie a modele perdu |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3288699A1 true EP3288699A1 (fr) | 2018-03-07 |
EP3288699B1 EP3288699B1 (fr) | 2023-08-02 |
Family
ID=53366209
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP16722312.2A Active EP3288699B1 (fr) | 2015-04-30 | 2016-04-26 | Procede de fabrication de modele pour fonderie a modele perdu |
Country Status (5)
Country | Link |
---|---|
US (1) | US10913105B2 (fr) |
EP (1) | EP3288699B1 (fr) |
CN (1) | CN107645974A (fr) |
FR (1) | FR3035604B1 (fr) |
WO (1) | WO2016174344A1 (fr) |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB939328A (en) * | 1961-01-27 | 1963-10-09 | Howe Sound Co | Apparatus and method for the production of cored patterns |
US3981344A (en) * | 1974-08-21 | 1976-09-21 | United Technologies Corporation | Investment casting mold and process |
GB2150874B (en) * | 1983-12-07 | 1986-07-09 | Rolls Royce | Investment casting |
US5465780A (en) * | 1993-11-23 | 1995-11-14 | Alliedsignal Inc. | Laser machining of ceramic cores |
DE10038453A1 (de) * | 2000-08-07 | 2002-02-21 | Alstom Power Nv | Verfahren zur Herstellung eines gekühlten Feingussteils |
EP1353786A1 (fr) * | 2000-12-19 | 2003-10-22 | PCC Structurals, Inc. | Outil de soudure pour gabarit de moulage et son procede d'utilisation |
EP1930096A1 (fr) | 2006-12-07 | 2008-06-11 | Siemens Aktiengesellschaft | Procédé de fabrication de modèles pour la fonderie en cire perdue des pièces contenants au moins une cavité |
US7674093B2 (en) | 2006-12-19 | 2010-03-09 | General Electric Company | Cluster bridged casting core |
US7942188B2 (en) | 2008-03-12 | 2011-05-17 | Vent-Tek Designs, Llc | Refractory metal core |
FR2995807B1 (fr) | 2012-09-25 | 2015-10-09 | Snecma | Moule carapace a ecran thermique |
-
2015
- 2015-04-30 FR FR1553937A patent/FR3035604B1/fr active Active
-
2016
- 2016-04-26 WO PCT/FR2016/050980 patent/WO2016174344A1/fr active Application Filing
- 2016-04-26 EP EP16722312.2A patent/EP3288699B1/fr active Active
- 2016-04-26 CN CN201680026737.8A patent/CN107645974A/zh active Pending
- 2016-04-26 US US15/570,011 patent/US10913105B2/en active Active
Also Published As
Publication number | Publication date |
---|---|
EP3288699B1 (fr) | 2023-08-02 |
FR3035604A1 (fr) | 2016-11-04 |
US10913105B2 (en) | 2021-02-09 |
WO2016174344A1 (fr) | 2016-11-03 |
FR3035604B1 (fr) | 2023-01-13 |
CN107645974A (zh) | 2018-01-30 |
US20180154427A1 (en) | 2018-06-07 |
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