WO2005123302A1

WO2005123302A1 - Process for manufacturing rotor-compressors of turbo-compressors and other difficult-to-extract parts, and corresponding mould

Info

Publication number: WO2005123302A1
Application number: PCT/BR2005/000118
Authority: WO
Inventors: Élio de Mello CASTANHO JÚNIOR
Original assignee: FELIPPI, Ezídio
Priority date: 2004-06-18
Filing date: 2005-06-17
Publication date: 2005-12-29
Also published as: BRPI0402480A

Abstract

The present patent refers to a process for manufacturing rotors of turbochargers and other parts difficult to extract by injection of aluminum or other metals or metallic leagues or polymers in a mould with segmented insert (1), sliding drawers (2) and drawing sets (3), aiming a better quality and a better finishing for the piece, without needing for hardening, with a better reproducibility of the pieces using a same nondestructive mould, possibility of extracting complex geometry pieces without deformation, homogeneous and flat, having obtained pieces greater mechanical and thermal resistance, larger durability, smaller friction and smaller working temperature in case of rotors for turbochargers.

Description

"PROCESS FOR MANUFACTURING ROTOR-COMPRESSOR OF TURBO-COMPRESSORS AND OTHER DIFFICULT-TO-EXTRACT PARTS, AND CORRESPONDING MOULD". The present patent of invention refers to a process for manufactøing rotors of turbochargers and other parts difficult to extract by injection of aluminum or other metals or metallic blends or polymers in a mould specially designed to open three-dimensionally and to provide easy extraction of the molded product within a totally new concept, aiming a better quality and a better fmishing for the product, without needing for hardening, with a better reproducibility of the products using a same non-destructive mould, possibility of extracting complex geometry products without deformation, homogeneous and flat, having obtained products with greater mechanical and thermal resistance, larger durability, smaller friction and smaller working temperature in case of rotors for turbochargers. As it is well known by technicians in the branch of manufacture of rotors for vehicular turbochargers, currently the rotors-compressors have a design with complex geometry, endowed of blades helically twisted in the axial direction, that increase diameter, in an axial direction and decrease in the other ones. Presently, for manufacturing this kind of rotors or others products of complex geometries, there are basically the following processes and corresponding moulds: 1) Aluminum casting in an ingot mould with sand or another previously formatted mineral material starting from a polymeric mould, which is difficult to extract when the product geometry is complex with curves fins, needing hardening, besides producing a low-quality product with high porosity that generate much friction at high revolution speeds with elevation of temperature and bubbles that decrease its mechanical resistance, limit shelf life of the product and have a high cost due to the necessary workmanship and to disposability of the die; and 2) More recently, arose an evolution in the branch, through a device that previously manufactures dies of plaster under vacuum, in which the products are cast in aluminum, still with high cost, although time expense has decreased by corresponding decrease in workmanship, but still with the need for a disposable die and hardening process, besides producing low quality products with porosity that much friction at high revolution speeds with elevation of temperature and bubbles that decrease its mechanical resistance, and limit shelf life of the product, due to occurrence of fatigue, disintegration and cracking. "PROCESS FOR MANUFACTURING ROTOR- COMPRESSOR OF TURBO-COMPRESSOR AND OTHER DIFFICULT-TO- EXTRACT PARTS, AND CORRESPONDING MOULD", object of the present patent, was developed to solve the problems and inconvenient of the current products and processes and, by using injection process with a mould especially designed to open three-dimensionally and to provide easy extraction of the molded product with a totally new concept, aiming a better quality and a better finishing for the product, without needing for hardening, with a better reproducibility of the products using a same non- destructive mould, possibility of extracting complex geometry products without deformation, homogeneous and flat, having obtained products with greater mechanical and thermal resistance, larger durability, smaller friction and smaller working temperature in case of rotors for turbochargers. For a better understanding of the present Invention, the following drawings are attached: FIGURE 1., which shows the block diagram with the sequence of the manufactrjring process of the present patent; FIGURE 2., which shows perspective view of the corresponding mould for die-casting a rotor with twelve blades; FIGURE 3., which shows a superior view of the corresponding mould for die-casting a rotor with twelve blades, with drawers in the closed position; FIGURE 4., which shows a superior view of the corresponding mould for die-casting a rotor with twelve blades, with drawers in the open position; and FIGURE 5., which shows a side view of the corresponding mould for die-casting a rotor with twelve blades, with drawers in the closed position; According to the referred figures, the packing process has the following sequence: a) The mould is assembled, by positioning the segmented blocks ( 1 ) to perform the geometry of the product ( P ), in case of compression rotors with two or more blades, fastened in the sliding drawers ( 2 ) with the same number of sections as that from the blocks ( 1 ) and these blocks cased in drawer sets ( 3 ) with the same number of sections as that from the blocks

( i ); b) The reservoir of molten aluminum, or another metal or metallic(s) alloy(s) or polymer conventionally spills the previously calibrated quantity of material in the injection sleeve and the injection machine conventionally injects the molten material in the cavity ( C ) formed inside the mould; c) The mould with the injected product is dislocated removing the machine injection sleeve, which remains in a resting position, from the mould, in so exposing the product ( P ); and d) The conventional extractor hydraulic piston softly activates the bottom of the drawers ( 2 ) dislocating the same in the channels ( 3-A ) of the respective drawers ( 3 ), occurring a three-dimensional opening with retreat of the blocks ( 1 ) that form injection channels for the product ( P ), due to the angle of the channels ( 3-A ) of the drawers ( 2 ) which gradually retreat from the injected product, completing the extraction and liberating the injected product (

P ). The mould corresponding to the process of the present patent is constituted of segmented blocks ( 1 ) of complementary formats with hollows and prominences, which when being placed side by side in circular fashion form a cavity ( C ) with the same format as the format of the wished product ( P ), fastened in the shding drawers ( 2 ) through the screws ( 2 A ) or another mean for conventional fixation, sliding drawers ( 2 ) in form of wedge, straight or helical, with the same number of sections as the blocks ( 1 ), endowed of guides ( 2-B ) with a transversal section in " T " form, straight or helical, consolidated in its external part in a radial form and cased in drawers ( 3 ) through the guides ( 2-B ) and a set of drawers ( 3 ) of cylindrical or polygonal format, distributing the channels ( 3 A) in a radial form, with channels ( 3 A ) with the same number of sections as that from the blocks ( 1 ) and as that from the drawers ( 2 ) and with a transversal section in form of " T " straight or helical.

Claims

1 "PROCESS FOR MANUFACTURING

ROTOR-COMPRESSOR OF TURBO-COMPRESSORS AND OTHER DIFFICULT-TO-EXTRACT PARTS ", characterized by the following sequence: a) The mould is assembled, by positioning the segmented blocks ( 1 ) to perform the geometry of the product ( P ), in case of compression rotors with two or more blades, fastened in the shding drawers ( 2 ) with the same number of sections as that from the blocks ( 1 ) and these blocks cased in drawer sets ( 3 ) with the same number of sections as that from the blocks

( i ); b) The reservoir of molten alunώium, or another metal or metalhc(s) alloy(s) or polymer conventionally spills the previously calibrated quantity of material in the injection sleeve and the injection machine conventionally injects the molten material in the cavity ( C ) formed inside the mould; c) The mould with the injected product is dislocated removing the machine injection sleeve, which remains in a resting position, from the mould, in so exposing the injected product ( P ); and d) The conventional extractor hydraulic piston softly activates the bottom of the drawers ( 2 ) dislocating the same in the channels ( 3-A ) of the respective drawers ( 3 ), occurring a toee-dimensional opening with retreat of the blocks ( 1 ) that form injection channels for the product ( P ), due to the angle of the channels ( 3-A ) of the drawers ( 2 ) which gradually retreat from the injected product, completing the extraction and liberating the injected product (

P )-

2. "MOULD", characterized by, segmented blocks (

1 ) of complementary formats with hollows and prominences, which when being placed side by side in circular fashion form a cavity ( C ) with the same format as the format of the wished product ( P ), fastened in the sliding drawers ( 2 ) through the screws ( 2 A ) or another mean for conventional fixation, sliding drawers ( 2 ) in form of wedge, straight or helical, with the same number of sections as the blocks ( 1 ), endowed of guides ( 2-B ) with a transversal section in " T " form, straight or helical, consolidated in its external part in a radial form and cased in drawers ( 3 ) through the guides ( 2-B ) and a set of drawers ( 3 ) of cylindrical or polygonal format, distributing the channels ( 3-A ) in a radial form, with channels ( 3-A ) with the same number of sections as that from the blocks ( 1 ) and as that from the drawers ( 2 ) and with a transversal section in form of " T " straight or helical.