JP2015123497A - Manufacturing method of casting component and core for manufacturing casting component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a casting component capable of improving inspection efficiency related to a flow rate test of a casting product having an internal cooling structure, and to provide a core for manufacturing the casting component.SOLUTION: A method in which molten metal 21 is supplied between a core 10 and a casting die 20 and, thereafter, the core 10 is removed to manufacture a casting component having a hollow part corresponding to the core 10 includes: a process of supplying the molten metal 21 between the core 10 having an extension part 12 on one edge and the casting die 20 to manufacture an intermediate casting component having a connection part corresponding to the extension part 12; a process of connecting a fluid supply pipe for connection part flow rate inspection of the intermediate casting component and supplying fluid to the hollow part; and a process of removing the connection part of the intermediate casting component after supplying the fluid. Therein, the extension part 12 has such a shape as to form a hollow connection part corresponding to an edge part of the fluid supply pipe connected to the hollow part.

Description

  The present invention relates to a method for manufacturing a cast part such as a turbine blade having an internal cooling structure and an engine block, and a core for manufacturing the cast part.

Conventionally, as a technique for manufacturing this type of cast part, a gas turbine rotor blade manufacturing method disclosed in Patent Documents 1 and 2 below is known.
These gas turbine rotor blades shown in Patent Documents 1 and 2 are cast parts produced by casting having a hollow cooling medium flow passage therein, and the cooling medium flow passage is formed therein. At this time, a core having the same shape as that of the cooling medium flow path is disposed, and the core is removed after casting.

JP 2002-28751 A Japanese Patent No. 3472931

  By the way, the gas turbine blade configured as described above has a structure in which the whole is cooled by flowing cooling air into a cooling medium flow passage formed in a hollow shape. For this reason, in order to form a hollow part in a cast part, the core is cast using a core, and the core is melted and removed with an alkaline solvent after casting.

  FIG. 6 shows an example of a gas turbine blade 2 having a hollow cooling medium flow passage 1 formed therein by a cast part. In the gas turbine blade 2 shown in this figure, in order to ensure cooling by flowing air through the hollow cooling medium flow passage 1, whether or not a prescribed flow rate flows as designed depends on whether the cooling medium flows after casting. The test is performed by a test air supply device 4 installed at the base end 3 of the flow passage 1.

However, in such a technique, a connecting jig (indicated by reference numeral 5) for connecting to a test air supply device 4 for supplying cooling air during flow rate inspection is interposed for each of the plurality of cooling medium flow paths 1. In each case, it is necessary to confirm the installation state of the connecting jig 5 so that there is no leakage at the seal portion.
That is, in the gas turbine blade 2 connected to the test air supply device 4 via the connection jig 5, (1) the connection jig 5 having the shape of the supply port of the cooling medium flow passage 1 is connected to the flow rate (2) The supply port of the cooling medium flow passage 1 needs to be created for each inspection. Since the surface after casting is not smooth, sealing may be difficult and cooling air may leak. These (1) and (2) There is a problem that the time and cost required for the flow rate inspection become enormous and the inspection efficiency is poor.

  The present invention has been made in view of the above-described circumstances, and manufactures a casting part manufacturing method and a casting part capable of improving inspection efficiency related to a flow rate test of a casting having an internal cooling structure. It provides a core for this purpose.

  In order to achieve the above object, according to one aspect of the present invention, a cast part having a hollow portion corresponding to the core is obtained by removing the core after supplying molten metal between the core and the mold. A molten metal is supplied between a core having an extension at one end and a mold to produce an intermediate cast part having a connection corresponding to the extension, and the intermediate Connecting a fluid supply pipe for flow rate inspection to the connection part of the cast part and supplying a fluid to the hollow part; and after supplying the fluid, removing the connection part of the intermediate cast part; The extension portion has a shape that forms the hollow connection portion corresponding to the end portion of the fluid supply pipe connected to the hollow portion.

And according to the said one aspect | mode, molten metal is supplied between the core which has an extension part in one end, and a casting_mold | template, and the intermediate casting component which has a connection part corresponding to this extension part is manufactured. Thereafter, a fluid supply pipe for flow rate inspection is connected to the connection part of the intermediate casting part to supply the fluid into the hollow part, thereby inspecting whether or not the design flow rate flows through the fluid supply pipe. After the inspection, the cast part is manufactured by removing the connection part of the intermediate cast part.
Here, the extension portion of the core has a shape that forms a hollow connection portion corresponding to the end portion of the fluid supply pipe connected to the hollow portion of the intermediate cast part. In the flow rate inspection, the fluid supply pipe for flow rate inspection can be matched with the hollow part shape formed in the connection part of the intermediate casting part. As a result, there is no need to create a connection jig to connect to the hollow part of the cast part for each flow rate inspection as before, and there is no air leakage due to a seal failure, so an efficient flow rate test. Can be carried out.

  Further, in the cast part manufacturing method of one aspect of the present invention, one end of the extension part of the core has a shape corresponding to an end part of the hollow part of the intermediate cast part, and the other end is for the flow rate inspection. It is good also as a shape corresponding to this fluid supply pipe.

  According to the above configuration, one end of the extension portion of the core has a shape corresponding to the end portion of the hollow portion of the intermediate cast part, and the other end of the extension portion of the core is a fluid supply for flow rate inspection. An extension of the core is formed to form a shape corresponding to the tube. As a result, the intermediate cast part after casting can be connected and connected to the fluid supply pipe for flow rate inspection without any trouble through the connecting portion without using a special connecting jig.

  Further, in the method of manufacturing a cast part according to one aspect of the present invention, the extension portion of the core is between the cross-sectional shape of the end portion on the hollow portion side and the cross-sectional shape of the end portion on the fluid supply pipe side. The outer diameter may gradually change.

  According to the above configuration, the outer diameter of the extension portion of the core gradually changes between the cross-sectional shape of the end portion on the hollow portion side and the cross-sectional shape of the end portion on the fluid supply pipe side. . For example, the extension of the core is formed so that the outer cross-sectional shape of the end on the fluid supply pipe side gradually increases toward the cross-sectional shape of the end on the hollow portion side of the intermediate cast part. Thereby, the connection part of the intermediate cast part after casting can also be formed in the same shape. As a result, in the intermediate cast part after casting, the inspection fluid from the fluid supply pipe for flow rate inspection can be smoothly guided into the hollow portion via the connection portion.

  In the method for manufacturing a cast part according to one aspect of the present invention, the cast part may be a turbine blade, and a hollow portion formed therein may serve as a passage for an internal cooling fluid of the turbine blade.

  And according to the said structure, a casting component is a turbine blade, The hollow part formed in the inside has the internal cooling flow path as a design by forming the channel | path of the internal cooling fluid of this turbine blade. Turbine blades can be manufactured.

  In addition, the core of the present invention is a core that is used for manufacturing a cast part by molten metal supplied between the mold after being installed in the mold and forms a hollow portion that serves as a fluid flow passage of the cast part. A main body and an extension connected to the core main body, one end having a shape corresponding to the end of the hollow portion of the intermediate cast part, and the other end having a shape corresponding to the fluid supply pipe for flow rate inspection; It is characterized by comprising.

According to the core of one aspect of the present invention, by supplying molten metal between the core having an extension at one end and the mold, an intermediate cast part having a connection corresponding to the extension is obtained. Manufactured. Thereafter, a fluid supply pipe for flow rate inspection is connected to the connection part of the intermediate cast part, and a fluid is supplied into the hollow part, thereby inspecting whether the design flow rate flows through the fluid supply pipe. . Then, after the inspection, the connection part of the intermediate cast part is removed.
At this time, the extension portion of the core has a shape that forms a hollow connection portion corresponding to the end portion of the fluid supply pipe connected to the hollow portion of the intermediate cast part. In the flow rate inspection, the fluid supply pipe for the flow rate inspection can be matched with the shape of the hollow portion formed in the connection portion of the intermediate cast part. As a result, it is not necessary to prepare a connection jig for each flow rate inspection as before, and air leakage due to a sealing failure is eliminated, and an efficient flow rate test can be performed.

  In the core of one aspect of the present invention, the core body and the extension may be formed integrally, or the core body and the extension may be formed separately and bonded to each other. good.

  And according to the above-described core, the core body and the extension located at the end thereof are integrally formed, or the core body and the extension located at the end thereof are formed separately. And are bonded to each other. And a core can be efficiently manufactured by selecting these core structures suitably.

According to the present invention, molten metal is supplied between a core having an extension at one end and a mold to produce an intermediate cast part having a connection corresponding to the extension. Thereafter, a fluid supply pipe for flow rate inspection is connected to the connection part of the intermediate casting part to supply the fluid into the hollow part, thereby inspecting whether or not the design flow rate flows through the fluid supply pipe. After the inspection, the cast part is manufactured by removing the connection part of the intermediate cast part.
Here, the extension portion of the core has a shape that forms a hollow connection portion corresponding to the end portion of the fluid supply pipe connected to the hollow portion of the intermediate cast part. In the flow rate inspection, the fluid supply pipe for flow rate inspection can be matched with the hollow part shape formed in the connection part of the intermediate casting part. As a result, there is no need to create a connection jig to connect to the hollow part of the cast part for each flow rate inspection as before, and there is no air leakage due to a seal failure, so an efficient flow rate test. Can be carried out.

It is a front view which shows the preparation process of the ceramic core which concerns on one Embodiment of this invention. It is a figure which shows the process of setting a ceramic core to a casting_mold | template, (A) is a front sectional view, (B) is sectional drawing which follows the bb line of (A). It is a figure which shows the process of pouring a molten metal in a casting_mold | template, (A) is a front sectional view, (B) is the sectional drawing. It is a figure of the cast component after melt | dissolving a ceramic core and removing a casting_mold | template, Comprising: (A) is a front sectional view, (B) is the sectional drawing. It is a figure which shows the flow rate test of casting components, Comprising: (A) is a front sectional view, (B) is the sectional drawing. It is a figure which shows the conventional casting components, Comprising: (A) is a front sectional view, (B) is sectional drawing which follows the bb line of (A).

An embodiment of the present invention will be described with reference to FIGS.
First, what is denoted by reference numeral 10 in FIG. 1 is a ceramic core according to the present invention, which is placed in a mold 20 and then is supplied with the molten metal 21 between the mold 20 to produce an intermediate cast part D ′ and It is used to manufacture a cast part D that is the final product (described later).
Further, the ceramic core 10 is located on the upper side in FIG. 1 and has a core body 11 for forming a hollow portion C serving as a fluid flow passage in the cast part D, and a lower base of the core body 11. And an extension portion 12 formed at an end portion. The extension 12 is shaped to form a hollow connection end 40 corresponding to the end of the fluid supply pipe 30 connected to the hollow part C of the cast part D at the base end of the cast part D. Is set (described later).
Here, the extension portion 12 of the ceramic core 10 has a gradually outer diameter between the cross-sectional shape of the end portion on the hollow portion C side of the cast part D and the cross-sectional shape of the end portion on the fluid supply pipe 30 side. It is formed to change. For example, the extension portion of the ceramic core 10 is formed such that the outer cross-sectional shape of the end portion on the fluid supply pipe 30 side gradually increases toward the cross-sectional shape of the end portion on the hollow portion C side of the cast part D. 12 is formed (described later).

The ceramic core 10 is manufactured by a precision casting method (lost wax method) in which a mixture of ceramic powder and wax is poured into a mold and fired.
In the ceramic core 10, the core body 11 and the extension 12 may be integrally formed by a precision casting method, or the core body 11 and the extension 12 are formed separately. They may be bonded together and integrated.

Next, the manufacturing method of the casting component D using the ceramic core 10 is demonstrated with reference to FIGS.
(Core preparation process)
First, the ceramic core 10 having the core body 11 and the extension 12 as shown in FIG. 1 is prepared by precision casting.

(Process to install the core in the mold)
Next, as shown in FIGS. 2A and 2B, the ceramic core 10 shown in FIG. At this time, the gap 13 between the ceramic core 10 and the mold 20 is filled with wax (not shown) to hold the ceramic core 10 at a predetermined position in the mold 20.

(Molded metal pouring process)
Next, as shown in FIGS. 3A and 3B, molten metal 21 is poured into the gap 13 between the ceramic core 10 and the mold 20, thereby removing the wax (not shown) in the gap 13. Dissolve and replace with molten metal 21.

(Process for forming intermediate cast parts)
Next, as shown in FIGS. 4A and 4B, after the molten metal 21 is cooled, the ceramic core 10 is alkali-dissolved and the outer mold 20 is removed, whereby a fluid supply pipe for flow rate inspection. An intermediate cast part D ′ having a connecting end 40 that can be connected to 30 is formed.
The hollow shape in the connection end portion 40 of the intermediate cast part D ′ is formed by the extension portion 12 of the ceramic core 10 corresponding to the shape of the connection portion with the fluid supply pipe 30 for flow rate inspection, as described above. Is done.

(Flow rate inspection process)
Next, as shown in FIGS. 5A and 5B, the fluid supply pipe 30 for flow rate inspection is connected to the connection end 40 of the intermediate casting part D ′, and the inspection fluid is supplied to the hollow portion C. To do. Thus, it is tested whether or not a fluid having a flow rate as designed flows through the hollow portion C of the intermediate cast part D ′.
When the connection end 40 of the intermediate casting part D ′ is connected to the fluid supply pipe 30 for flow rate inspection, the hollow shape in the connection end 40 of the intermediate casting part D ′ is the extension 12 of the ceramic core 10. The connection part shape with the fluid supply pipe 30 for flow rate inspection is provided. For this reason, the hollow shape formed in the connection end portion 40 of the intermediate casting part D ′ can be matched with the shape of the connecting portion of the fluid supply pipe 30 for flow rate inspection. Can be prevented.
In FIG. 5 (A), what is indicated by reference numerals 31 and 32 is a support portion that supports the intermediate casting part D ′ and its connection end 40 at the time of the flow rate inspection. It also serves as a lid for the hollow portion C in the intermediate cast part D ′.

(Connection end removal process)
After supplying the inspection fluid, the connection end 40 of the intermediate cast part D ′ is removed as shown by the cutting line a in FIG.

As described above in detail, in the method for manufacturing a cast part according to this embodiment, the molten metal 21 is supplied between the ceramic core 10 having the extension 12 at one end and the mold 20, and the extension 12 is supplied to the extension 12. An intermediate cast part D ′ having a corresponding connecting end 40 is produced. Thereafter, the fluid supply pipe 30 for flow rate inspection is connected to the connection end 40 of the intermediate casting part D ′, and the inspection fluid is supplied into the hollow part C. Inspect whether the flow is flowing. After the inspection, the cast part D is manufactured by removing the connection end 40 of the intermediate cast part D ′.
Here, the extension 12 of the ceramic core 10 has a shape that forms a hollow connection end 40 corresponding to the end of the fluid supply pipe 30 connected to the hollow C of the intermediate casting part D ′. In the flow rate inspection after manufacturing the intermediate cast part D ′, the fluid supply pipe 30 for flow rate inspection can be matched with the hollow portion C shape formed in the connection end 40 of the intermediate cast part D ′. it can. As a result, there is no need to create a connection jig to connect to the hollow part of the cast part for each flow rate inspection as before, and there is no fluid leakage due to a seal failure, so an efficient flow rate test. Can be carried out.

  In the method for manufacturing a cast component according to the present embodiment, one end of the extension 12 of the ceramic core 10 has a shape corresponding to the end of the hollow portion C of the intermediate cast component D ′. The extension 12 of the ceramic core 10 is formed so that the other end of the extension 12 has a shape corresponding to the fluid supply pipe 30 for flow rate inspection. As a result, the intermediate cast part D ′ after casting can be connected and connected to the fluid supply pipe 30 for flow rate inspection without any trouble through the connection end portion 40 without using a special connection jig. .

  In the method for manufacturing a cast component according to the present embodiment, the extension 12 of the ceramic core 10 has a cross-sectional shape at the end on the hollow portion C side and a cross-sectional shape at the end on the fluid supply pipe 30 side. The outer diameter gradually changes between For example, the outer diameter of the ceramic core 10 is gradually increased so that the cross-sectional shape of the end portion on the fluid supply pipe 30 side gradually increases toward the cross-sectional shape of the end portion on the hollow portion C side of the intermediate cast part D ′. By forming the extension part 12, the connection end part 40 of the intermediate cast part D ′ after casting can be formed in the same shape. As a result, in the intermediate cast part D ′ after casting, the inspection fluid from the fluid supply pipe 30 for flow rate inspection can be smoothly guided into the hollow portion C via the connection end 40.

  Moreover, in the manufacturing method of the cast component according to the present embodiment, the turbine blade is formed by the cast component D, and the hollow portion C formed therein forms a passage for the internal cooling fluid of the turbine blade. It is possible to manufacture a turbine blade having an internal cooling channel as designed.

On the other hand, according to the ceramic core 10 according to the present embodiment, the extension portion 12 located at the lower end corresponds to the end of the fluid supply pipe 30 connected to the hollow portion C of the intermediate casting part D ′. Since it is a shape that forms the hollow connection end portion 40, the shape of the hollow portion C formed at the connection end portion 40 of the intermediate casting part D ′ during the flow rate inspection after manufacturing the intermediate casting part D ′. In addition, the fluid supply pipe 30 for flow rate inspection can be matched. As a result, there is no need to create a connection jig to connect to the hollow part of the cast part for each flow rate inspection as before, and there is no fluid leakage due to a seal failure, so an efficient flow rate test. Can be carried out.
Further, according to the ceramic core 10, the core body 11 and the extension 12 positioned at the end thereof are integrally formed, or the core body 11 and the extension 12 positioned at the end thereof are separated. It is the structure formed in a body and mutually adhere | attached. Then, by appropriately selecting these core structures, the ceramic core 10 can be manufactured efficiently.

  In the method of manufacturing a cast component according to the present embodiment, a turbine blade having a hollow internal cooling fluid passage may be formed. However, the present invention is not limited thereto, and a cast component such as an engine block is manufactured. The type of cast part is not particularly limited.

  As mentioned above, although embodiment of this invention was explained in full detail with reference to drawings, the concrete structure is not restricted to this embodiment, The design change etc. of the range which does not deviate from the summary of this invention are included.

  The present invention relates to a method for manufacturing a cast part such as a turbine blade having an internal cooling structure and an engine block, and a core for manufacturing the cast part.

DESCRIPTION OF SYMBOLS 10 Ceramic core 11 Core main body 12 Extension part 20 Mold 21 Molten metal 30 Fluid supply pipe 40 Connection end part (connection part)
D Casting part D 'Intermediate casting part C Hollow part

Claims (7)

A method for producing a cast part having a hollow portion corresponding to the core by removing the core after supplying molten metal between the core and the mold,
Supplying molten metal between a core having an extension at one end and a mold to produce an intermediate cast part having a connection corresponding to the extension; and
Connecting a fluid supply pipe for flow rate inspection to the connection part of the intermediate cast part and supplying a fluid to the hollow part;
After supplying the fluid, removing the connecting portion of the intermediate cast part,
The extension part has a shape that forms the hollow connection part corresponding to an end part of a fluid supply pipe connected to the hollow part.   One end of the extension portion of the core has a shape corresponding to the end of the hollow portion of the intermediate cast part, and the other end has a shape corresponding to the fluid supply pipe for the flow rate inspection. A method for producing a cast part according to claim 1.   The extension portion of the core has an outer diameter that gradually changes between a cross-sectional shape of an end portion on the hollow portion side and a cross-sectional shape of an end portion on the fluid supply pipe side. 2. A method for producing a cast part according to 2.   The method of manufacturing a cast part according to any one of claims 1 to 3, wherein the cast part is a turbine blade, and a hollow portion formed in the cast part is a passage for an internal cooling fluid of the turbine blade. A core for producing a cast part by molten metal supplied between the mold after being installed in the mold,
A core body that forms a hollow portion that serves as a fluid flow path of the cast part, and is connected to the core body, and one end has a shape corresponding to the end of the hollow part of the intermediate cast part, and the other end is the flow rate And a core having a shape corresponding to a fluid supply pipe for inspection.   The core according to claim 5, wherein the core body and the extension are integrally formed.   The core according to claim 5, wherein the core body and the extension are formed separately and are bonded to each other.

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