《Turbine Blade Investment Casting Die Technology》

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《Turbine Blade Investment Casting Die Technology》
涡轮叶片精密铸造模具技术
作者：
Dinghua Zhang
Yunyong Cheng
Ruisong Jiang
Neng Wan
翻译：
Kuidong Huang
Wenhu Wang
Kun Bu
出版社：Springer
出版时间：2018年

《Turbine Blade Investment Casting Die Technology》

目录
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Turbine Blade of Aero-Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Introduction of Aero-Engine . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Turbine Blade of Aero-Engine . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Investment Casting Process of Turbine Blade. . . . . . . . . . . . . . . . . 7
1.2.1 The Main Processes of Investment Casting . . . . . . . . . . . . . 7
1.2.2 Main Issues in Investment Casting of Turbine Blade . . . . . 8
1.3 Literature Review of Investment Casting Die Technology . . . . . . . 9
1.3.1 Parametric Modeling for Turbine Blade . . . . . . . . . . . . . . . 9
1.3.2 Intelligent Design for Investment Casting Die. . . . . . . . . . . 10
1.3.3 Optimization of Investment Casting Die Cavity . . . . . . . . . 13
1.3.4 NDT of Investment Casting Blade
and Rapid Finalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 The Developmental Trends in Turbine Blade Investment
Casting Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Digitized Modeling Technology of Turbine Blade. . . . . . . . . . . . . . . . 21
2.1 Structural Features Classification of Turbine Blade . . . . . . . . . . . . 21
2.1.1 Structural Elements Classification of Turbine Blade . . . . . . 21
2.1.2 Feature Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.1.3 Feature Definitions of Turbine Blade Structure . . . . . . . . . . 25
2.2 Parametric Modeling of Structural Features . . . . . . . . . . . . . . . . . . 27
2.2.1 Design Process of Turbine Blade . . . . . . . . . . . . . . . . . . . . 27
2.2.2 Basic Principle of Parametric Modeling . . . . . . . . . . . . . . . 28
2.2.3 Datum Feature of Turbine Blade Modeling. . . . . . . . . . . . . 31
2.2.4 Surface Modeling of Turbine Blade . . . . . . . . . . . . . . . . . . 32
2.2.5 Internal Profile Feature Modeling of Turbine Blade . . . . . . 44
2.2.6 Typical Feature Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . 50
vii
2.3 Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Cavity Design Method for Investment Casting Die of Turbine
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Multistate Model Transformation Method for Investment
Casting Die Cavity of Turbine Blade . . . . . . . . . . . . . . . . . . . . . . . 63
3.1.1 Definition of Multistate Model of Investment Casting
Die Cavity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1.2 Investment Casting Process Driven Multistate Model
Transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1.3 Geometric Information Mapping for Multistate Model
Based on Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Parting Technologies for Investment Casting Die Cavity . . . . . . . . 74
3.2.1 The Parting Principle Based on Feature Decomposition . . . 75
3.2.2 The Die Cavity Feature Decomposition Method . . . . . . . . . 76
3.2.3 Rule-Based Parting Method of Die Cavity . . . . . . . . . . . . . 78
3.3 Design Examples of Investment Casting Die Cavity. . . . . . . . . . . . 82
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Design of the Die Base for the Investment Casting Turbine
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Definition and Structure of the Knowledge Template
of Die Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1.1 Typical Structure of the Base of the Investment
Casting Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1.2 The Definition of the Knowledge Template
for the Die Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1.3 Structure and Data Model of the Knowledge Template
for the Die Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 The Method to Construct a Knowledge Template
for Investment Casting Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2.1 The Procedures to Construct a Knowledge Template
for the Die Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2.2 Extraction of the Knowledge Template . . . . . . . . . . . . . . . . 95
4.2.3 Customization of the Knowledge Template
for the Die Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3 Rapid Design of Investment Casting Die Base Based
on the Knowledge Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3.1 Rapid Design Method of the Die Base . . . . . . . . . . . . . . . . 101
4.3.2 Design Example with the Template. . . . . . . . . . . . . . . . . . . 103
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
viii Contents
5 Deformation Simulation of Investment Casting and Die Cavity
Optimization of Turbine Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Deformation Simulation of Turbine Blade Investment
Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1.1 Investment Casting Simulation Modeling . . . . . . . . . . . . . . 105
5.1.2 Finite Element Modeling Investment Casting . . . . . . . . . . . 112
5.1.3 Investment Casting Simulation . . . . . . . . . . . . . . . . . . . . . . 115
5.2 The Analysis Calculation of the Simulation of Investment
Casting Deformation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2.1 The Distribution Regularity of Turbine Blade Surface
Size Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2.2 The Definition of the Displacement Field
of Solidification Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.2.3 The Calculate Method of Displacement Field . . . . . . . . . . . 136
5.2.4 Vector Expression and Vector Resolution of the
Displacement Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2.5 The Establishment of Displacement Field Model . . . . . . . . 141
5.3 Reserve Deformation Optimization and Virtual Mold Repair
of the Mold Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.3.1 Calculating Methods of Cavity Size . . . . . . . . . . . . . . . . . . 142
5.3.2 The Method of Reverse Deformation of Cavity . . . . . . . . . 146
5.3.3 Reverse Superposition Method of Grid Displacement
Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.3.4 Cavity Optimization Based on Superimposed
Displacement Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.3.5 Scaling Method Based on Shrinkage Ratio . . . . . . . . . . . . . 156
5.4 The Rapid Verification Technologies of Cavity Optimization. . . . . 166
5.4.1 Die Cavity Validation Scheme Based on Wax
Pattern NC Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.4.2 Wax Material Craft Process and Machining Parameter
Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.4.3 NC Machining Post Processing of Wax Material . . . . . . . . 169
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6 The Manufacturing and Finalization of the Turbine Blade
Investment Casting Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1 The Manufacturing Process of the Turbine Blade Investment
Casting Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1.1 The Structural Features of the Turbine Blade Investment
Casting Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1.2 The Manufacturing Process of the Turbine Blade
Investment Casting Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Contents ix
6.2 The Process Plan of the Turbine Blade Investment
Casting Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6.2.1 Materials Selection for Die Manufacturing . . . . . . . . . . . . . 176
6.2.2 The Process Planning for Die Manufacturing . . . . . . . . . . . 178
6.2.3 The Design of the Second Tooling Electrode . . . . . . . . . . . 182
6.2.4 The Selection of the Process Ball . . . . . . . . . . . . . . . . . . . . 185
6.3 The Machining Technology of the Turbine Blade Investment
Casting Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.3.1 The Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . 185
6.3.2 Nontraditional Machining Technologies in Die
Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.3.3 The Surface Treatment Technology. . . . . . . . . . . . . . . . . . . 198
6.3.4 The Repairing Technique . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.4 The Finalization of the Turbine Blade Investment
Casting Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.4.1 The Inspection of the Investment Casting Die. . . . . . . . . . . 206
6.4.2 The Testing of the Investment Casting Die . . . . . . . . . . . . . 207
6.4.3 The Finalization of the Investment Casting Die . . . . . . . . . 208
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7 Turbine Blade Investment Casting Experiment and Measurement
Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7.1 Investment Casting Experiment Process . . . . . . . . . . . . . . . . . . . . . 211
7.2 Blade Casting Geometrical Dimension Measurement and
Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7.2.1 Measurement Data Acquisition . . . . . . . . . . . . . . . . . . . . . . 213
7.2.2 Model Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7.2.3 Geometrical Shape Analysis . . . . . . . . . . . . . . . . . . . . . . . . 234
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

中文版的

《Turbine Blade Investment Casting Die Technology》