Turbine Blade Investment Casting Die Technology (eBook)

Preface 5
Contents 7
Introduction 11
1 Introduction 12
1.1 Turbine Blade of Aero-Engine 12
1.1.1 Introduction of Aero-Engine 12
1.1.2 Turbine Blade of Aero-Engine 14
1.2 Investment Casting Process of Turbine Blade 18
1.2.1 The Main Processes of Investment Casting 18
1.2.2 Main Issues in Investment Casting of Turbine Blade 19
1.3 Literature Review of Investment Casting Die Technology 20
1.3.1 Parametric Modeling for Turbine Blade 20
1.3.2 Intelligent Design for Investment Casting Die 21
1.3.3 Optimization of Investment Casting Die Cavity 24
1.3.4 NDT of Investment Casting Blade and Rapid Finalization 25
1.4 The Developmental Trends in Turbine Blade Investment Casting Technology 27
References 29
2 Digitized Modeling Technology of Turbine Blade 32
2.1 Structural Features Classification of Turbine Blade 32
2.1.1 Structural Elements Classification of Turbine Blade 32
2.1.2 Feature Modeling 35
2.1.3 Feature Definitions of Turbine Blade Structure 36
2.2 Parametric Modeling of Structural Features 38
2.2.1 Design Process of Turbine Blade 38
2.2.2 Basic Principle of Parametric Modeling 39
2.2.3 Datum Feature of Turbine Blade Modeling 42
2.2.4 Surface Modeling of Turbine Blade 43
2.2.5 Internal Profile Feature Modeling of Turbine Blade 55
2.2.6 Typical Feature Modeling 61
2.3 Case Study 71
References 72
3 Cavity Design Method for Investment Casting Die of Turbine Blade 74
3.1 Multistate Model Transformation Method for Investment Casting Die Cavity of Turbine Blade 74
3.1.1 Definition of Multistate Model of Investment Casting Die Cavity 75
3.1.2 Investment Casting Process Driven Multistate Model Transformation 76
3.1.3 Geometric Information Mapping for Multistate Model Based on Rules 78
3.2 Parting Technologies for Investment Casting Die Cavity 85
3.2.1 The Parting Principle Based on Feature Decomposition 86
3.2.2 The Die Cavity Feature Decomposition Method 87
3.2.3 Rule-Based Parting Method of Die Cavity 89
3.3 Design Examples of Investment Casting Die Cavity 93
References 94
4 Design of the Die Base for the Investment Casting Turbine Blade 95
4.1 Definition and Structure of the Knowledge Template of Die Base 97
4.1.1 Typical Structure of the Base of the Investment Casting Die 97
4.1.2 The Definition of the Knowledge Template for the Die Base 98
4.1.3 Structure and Data Model of the Knowledge Template for the Die Base 101
4.2 The Method to Construct a Knowledge Template for Investment Casting Die 104
4.2.1 The Procedures to Construct a Knowledge Template for the Die Base 104
4.2.2 Extraction of the Knowledge Template 105
4.2.3 Customization of the Knowledge Template for the Die Base 108
4.3 Rapid Design of Investment Casting Die Base Based on the Knowledge Template 111
4.3.1 Rapid Design Method of the Die Base 111
4.3.2 Design Example with the Template 113
References 114
5 Deformation Simulation of Investment Casting and Die Cavity Optimization of Turbine Blade 115
5.1 Deformation Simulation of Turbine Blade Investment Casting 115
5.1.1 Investment Casting Simulation Modeling 115
5.1.2 Finite Element Modeling Investment Casting 122
5.1.3 Investment Casting Simulation 125
5.2 The Analysis Calculation of the Simulation of Investment Casting Deformation 144
5.2.1 The Distribution Regularity of Turbine Blade Surface Size Errors 144
5.2.2 The Definition of the Displacement Field of Solidification Process 145
5.2.3 The Calculate Method of Displacement Field 146
5.2.4 Vector Expression and Vector Resolution of the Displacement Field 146
5.2.5 The Establishment of Displacement Field Model 151
5.3 Reserve Deformation Optimization and Virtual Mold Repair of the Mold Cavity 152
5.3.1 Calculating Methods of Cavity Size 152
5.3.2 The Method of Reverse Deformation of Cavity 156
5.3.3 Reverse Superposition Method of Grid Displacement Field 161
5.3.4 Cavity Optimization Based on Superimposed Displacement Field 162
5.3.5 Scaling Method Based on Shrinkage Ratio 166
5.4 The Rapid Verification Technologies of Cavity Optimization 176
5.4.1 Die Cavity Validation Scheme Based on Wax Pattern NC Machining 176
5.4.2 Wax Material Craft Process and Machining Parameter Optimization 178
5.4.3 NC Machining Post Processing of Wax Material 179
References 179
6 The Manufacturing and Finalization of the Turbine Blade Investment Casting Die 182
6.1 The Manufacturing Process of the Turbine Blade Investment Casting Die 182
6.1.1 The Structural Features of the Turbine Blade Investment Casting Die 182
6.1.2 The Manufacturing Process of the Turbine Blade Investment Casting Die 183
6.2 The Process Plan of the Turbine Blade Investment Casting Die 185
6.2.1 Materials Selection for Die Manufacturing 185
6.2.2 The Process Planning for Die Manufacturing 187
6.2.3 The Design of the Second Tooling Electrode 191
6.2.4 The Selection of the Process Ball 194
6.3 The Machining Technology of the Turbine Blade Investment Casting Die 194
6.3.1 The Machining Technology 194
6.3.2 Nontraditional Machining Technologies in Die Manufacturing 197
6.3.3 The Surface Treatment Technology 207
6.3.4 The Repairing Technique 213
6.4 The Finalization of the Turbine Blade Investment Casting Die 215
6.4.1 The Inspection of the Investment Casting Die 215
6.4.2 The Testing of the Investment Casting Die 216
6.4.3 The Finalization of the Investment Casting Die 217
References 218
7 Turbine Blade Investment Casting Experiment and Measurement Evaluation 219
7.1 Investment Casting Experiment Process 219
7.2 Blade Casting Geometrical Dimension Measurement and Evaluation 220
7.2.1 Measurement Data Acquisition 221
7.2.2 Model Alignment 235
7.2.3 Geometrical Shape Analysis 242
References 249