Casting method of low-vortex working blade

Abstract

The invention provides a casting method of a low-vortex working blade, which comprises the following steps of: S101, designing a test wax mold, and manufacturing the test wax mold conforming to the required blade through milling; step S102, designing a test module, combining a single formal wax mold with a pouring mechanism, and performing simulation and optimization on software; s103, a test wax mold shell is manufactured, the test wax mold shell and a test module are subjected to test casting together, and data analysis is conducted on the typical structure of a test casting; step S104, performing correction and reversible deformation test on a result of the step S103 to complete formal wax mold design; s105, formal module design is conducted, specifically, a plurality of formal wax molds and a pouring mechanism are combined, and the pouring mechanism comprises a T-shaped blind riser so that the rigidity of the blade can be improved; and S106, formal wax mold shell making is conducted, formal casting and iterative optimization are conducted together with a formal mold set, and casting parameters are continuously adjusted till a low-vortex working blade casting meeting the size and material standard is obtained, so that the problems that the blade is prone to being broken and the shrinkage rate is low are solved, and the consistency of the casting is improved.

Description

Technical Field

[0001] The invention relates to the technical field of blade casting molds, and more specifically to a casting method for low-vortex working blades. Background Art

[0002] In aircraft engines, the low-pressure turbine plays a key role in providing propulsion by extracting energy from the combustion gas to drive the fan. Especially in modern high-efficiency engines, such as the advanced Leap aircraft engine (Intercontinental engine), the design and manufacture of the low-pressure turbine has become particularly critical. The low-pressure turbine of these advanced engines usually has a complex structure, including multi-stage working blades and guide vanes. The number and shape of these blades have a significant impact on the performance of the engine. In order to improve aerodynamic efficiency, the low-pressure turbine blade adopts a "wide chord and narrow length" design, and the blade body is long and thin, which not only reduces the weight of the entire low-pressure turbine unit, but also improves the efficiency of the low-pressure turbine. However, this complex blade structure and special geometry make traditional casting methods face some challenges. The size and shrinkage of the blades need to be controlled very precisely to ensure the quality and performance of the blades.

[0003] Chinese patent CN 113466426 A discloses a method for obtaining the shrinkage rate of a sample casting, which can quickly and accurately obtain the shrinkage rate of different castings, but this method fails to solve the problem of how to accurately control the shrinkage rate and size of the blade, and does not accurately control the shrinkage rate of the blade. It also fails to solve the problem that during the manufacturing process, the blade is affected by the casting stress, which easily leads to the fracture or recrystallization of the blade or blade body.

[0004] Therefore, it is necessary to develop a new method or technology to solve the shortcomings of the method for obtaining the shrinkage rate of the sample casting. This new method should be able to quickly and accurately obtain the blade shrinkage rate and size, and most importantly, be able to achieve precise control of the blade shrinkage rate. Summary of the invention

[0005] The present invention provides a casting method for low-vortex working blades, aiming to solve the problems of easy breakage and shrinkage of blades, improve the rigidity of the blade body near the crown area, reduce stress concentration in specific areas of the blades, and improve the consistency of castings.

[0006] To achieve the above object, the present invention provides a casting method for the low-vortex working blade, comprising:

[0007] Step S101, designing a test wax mold, designing the shape, size and contour of the test wax mold according to the shape, size and contour of the required blade, and making a test wax mold that matches the required blade by milling;

[0008] Step S102, test module design, assembling the single test wax mold designed in step S101 and the casting mechanism into a test module, designing the size of the casting mechanism, and simulating and optimizing it on the software;

[0009] Step S103, test wax mold shell, and perform test casting together with the test module. After the casting is completed, obtain the test casting, perform three-dimensional size and relative position test on the typical structure of the test casting, obtain spatial size and position data, and calculate the structural characteristic shrinkage rate and relative position torsion offset;

[0010] Step S104, formal wax model design, correction and anti-deformation test are performed according to the result of step S103 to complete the shape, size and contour design of the formal wax model;

[0011] Step S105, formal module design, combining multiple formal wax molds and a casting mechanism, designing the size, cotton packing and mold shell of the casting mechanism, the casting mechanism includes a T-shaped blind riser to improve the rigidity of the blade;

[0012] Step S106, formal wax mold shell, formal casting and iterative optimization together with the formal mold set, constantly adjusting the casting parameters until a low-vortex working blade casting that meets the size and material standards is obtained.

[0013] In one embodiment, in step S101, the wax model includes a tenon, an extension root, a lip plate, a blade body, a blade shroud and a blade sealing tooth, and the dimensions of the tenon, the extension root, the lip plate, the blade body, the blade shroud and the blade sealing tooth are extracted when the shrinkage rate is zero.

[0014] In one embodiment, in step S101, the test wax model is made of the same material as the formal wax model, and the dimensions of the tenon, the extension root, the edge plate, the blade body, the blade crown and the blade sealing tooth under blue light or three-dimensional coordinates are recorded.

[0015] In one embodiment, in step S102, the test module design includes the size design of a single test wax mold and a pouring mechanism, and the pouring mechanism includes a pouring cup, a center pouring tube, a base, a pouring plate and a pouring runner assembly.

[0016] In one embodiment, in step S102, the parameters of the pouring tube, base, pouring plate and pouring runner combination size are simulated using Procast casting software to ensure sufficient pouring, record the location where the looseness occurs and optimize it, and do not pay attention to defects during software simulation.

[0017] In one embodiment, in step S103, the three-dimensional dimensions and relative position of the typical structures of the test casting, such as the tenon, the extension root, the edge plate, the blade body, the blade shroud and the blade sealing tooth, are tested to obtain the corresponding spatial dimensions and position, and then the structural characteristic shrinkage rate and relative position torsional offset of the tenon, the extension root, the edge plate, the blade body, the blade shroud and the blade sealing tooth are calculated.

[0018] In one embodiment, in step S104, according to the characteristic shrinkage rate and relative position torsion offset of the tenon, root extension, edge plate, blade body, blade crown and blade sealing tooth structure calculated in step S103, the characteristic structure is corrected and reversely deformed to complete the design of the formal wax model size.

[0019] In one embodiment, in step S105, the formal mold design includes the size design of multiple formal wax molds and the center injection tube, base, runner plate, runner assembly and T-shaped blind riser, cotton packing design and mold shell design.

[0020] In one embodiment, in step S105, the dimensions of the center injection pipe, base, runner plate and runner combination are determined based on experience and simulation software, and the elongation of the T-shaped area of ​​the T-shaped blind riser relative to the blade crown is designed to be twice the recrystallization or fracture position of the blade body in step S103.

[0021] In one embodiment, in step S106, iterative optimization includes: iteratively optimizing the wax mold shell and cotton packing design, continuously adjusting casting parameters and shell preheating parameters, and finally obtaining a low-vortex working blade casting whose metallurgical dimensions meet the drawing and material standards.

[0022] The present invention has the following beneficial effects:

[0023] 1. Wax block machining blade structure optimization method: The present invention proposes a wax block structure optimization method for machining blades. This method aims to quickly obtain the three-dimensional structure and characteristics of the blade while taking into account the shrinkage problem. By placing the shrinkage according to different structural features, the size and shape of the casting can be better controlled, which helps to improve mold preparation and casting size control.

[0024] 2. Innovation in T-shaped blind riser design: The present invention proposes an innovative blind riser design method to solve the problem of loose blade crown. This method not only helps to reduce the looseness of the blade crown, but also improves the rigidity of the blade body near the blade crown by designing a T-shaped blind riser. This helps to improve the deformation coordination between the blade crown and the blade body, reduce the stress concentration in specific areas of the blade, and thus reduce the stress of the blade body.

[0025] 3. Applicable to the casting of low-vortex blades of aircraft engines: The low-vortex blade casting scheme proposed by the present invention is applicable to the casting of low-vortex working blades of aircraft engines. This scheme has high consistency and is expected to have a wide range of application prospects in the aviation field because it can improve the quality, performance and production efficiency of castings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic flow chart of a casting method of a low-vortex working blade according to an embodiment of the present invention;

[0027] Figure 2 It is a schematic structural diagram of a test wax mold of a casting method for a low-vortex working blade according to an embodiment of the present invention;

[0028] Figure 3 It is a schematic structural diagram of a test module of a casting method for low-vortex working blades according to an embodiment of the present invention;

[0029] Figure 4 It is a structural schematic diagram of a formal mold of a casting method for low-vortex working blades according to an embodiment of the present invention.

[0030] Among them, 10 is the test wax model; 11 is the formal wax model; 21 is the pouring cup; 22 is the center injection tube; 23 is the base; 24 is the pouring plate; 25 is the pouring assembly; 26 is the T-shaped blind riser; 101 is the tenon; 102 is the extended root; 103 is the edge plate; 104 is the blade body; 105 is the blade crown; 106 is the blade sealing tooth. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical scheme and advantages of the implementation of this application clearer, the technical scheme in the embodiment of this application will be described in more detail below in conjunction with the drawings in the embodiment of this application. In the drawings, the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions. The described embodiments are part of the embodiments of this application, not all of them. The embodiments described below with reference to the drawings are exemplary and are intended to be used to explain this application, and should not be construed as limitations on this application. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0032] Figure 1 The present invention is a schematic flow chart of a method for casting a low-vortex working blade according to an embodiment of the present invention. The method for casting a low-vortex working blade includes:

[0033] Step S101, designing the test wax mold 10, designing the shape, size and contour of the test wax mold 10 according to the shape, size and contour of the required blade, and manufacturing the test wax mold 10 that matches the required blade by milling;

[0034] Step S102, test module design, assembling the single test wax mold 10 designed in step S101 and the casting mechanism into a test module, designing the size of the casting mechanism, and simulating and optimizing it on the software;

[0035] Step S103, the test wax mold 10 is shelled and tested together with the test mold. The test mold designed in step S102 is made, and the test wax mold 10 is wrapped with a shell material to form a mold shell. After removing the test wax mold 10, the mold shell and the pouring mechanism are assembled to form a test mold. The test casting is cast using the prepared test mold. After the casting is completed, the three-dimensional size and relative position accuracy of the typical structure of the test casting are tested to obtain the spatial size and position accuracy data, and the structural characteristic shrinkage rate and the relative position torsion offset are calculated;

[0036] Step S104, designing the formal wax model 11, performing correction and anti-deformation tests according to the results calculated in step S104, and completing the shape, size and contour design of the formal wax model 11;

[0037] Step S105, formal module design, combining multiple formal wax molds 11 and a casting mechanism, designing the size, cotton packing and mold shell of the casting mechanism, the casting mechanism includes a T-shaped blind riser 26 to improve the rigidity of the blade;

[0038] Step S106, the formal wax mold 11 is made into a shell, and formal casting and iterative optimization are carried out together with the formal module. The formal module designed in step S105 is made, and the formal wax mold 11 is wrapped with an outer shell material to form a mold shell. After removing the formal wax mold 11, the mold shell is assembled with the pouring mechanism to form a formal mold, and the obtained formal mold is used for pouring. The casting parameters when casting the formal casting are continuously adjusted until a low-vortex working blade casting that meets the size and material standards is obtained.

[0039] Specifically, in step S102, simulation software is used to perform simulation tests, and different design options can be compared to find the best test module parameters, including the location and size of the T-shaped blind riser 26, the gate and the cooling channel. The simulation software can also provide visualization tools to enable engineers to clearly see the filling and cooling process of the model, which helps to identify potential problems and improve the design. This helps to improve the quality of the model and reduce the scrap rate. Improve production efficiency, reduce costs and improve the quality of the final product.

[0040] Furthermore, step S106 is a practice process, during which the designer can further refine the solution and better control the casting process.

[0041] In one embodiment, the wax model includes a tenon 101, an extended root 102, a lip plate 103, a blade body 104, a blade crown 105 and a blade sealing tooth 106. In step S101, the dimensions of the tenon 101, the extended root 102, the lip plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 are extracted when the shrinkage rate is zero.

[0042] Specifically, it can ensure that the final manufactured part or product has very precise dimensions, and it can ensure that multiple parts produced in large quantities have consistent sizes and shapes, which is crucial for product interchangeability and consistency.

[0043] In one embodiment, in step S101 , the test wax model 10 is made of the same material as the formal wax model 11 , and the dimensions of the tenon 101 , the extension root 102 , the edge plate 103 , the blade body 104 , the blade crown 105 and the blade sealing tooth 106 are recorded under blue light or three-dimensional coordinates.

[0044] Specifically, blue light measurement has the advantages of non-contact, rapid, high-precision, and three-dimensional measurement, and three-coordinate measurement has the advantages of high precision, versatility, large size, and traceability. In the specific implementation process, the appropriate measurement method can be selected based on factors such as measurement accuracy, measurement speed, and the size and shape of the object being measured to ensure accurate dimensional data for quality control and manufacturing process improvement.

[0045] In one embodiment, in step S102 , the test module design includes the size design of a single test wax mold and a pouring mechanism, and the pouring mechanism includes a pouring cup 21 , a center pouring tube 22 , a base 23 , a pouring plate 24 and a pouring assembly 25 .

[0046] In one embodiment, in step S102, casting software such as Procast is used to simulate the size parameters of the center pouring pipe 22, the base 23, the runner plate 24 and the runner assembly 25 to ensure sufficient pouring, record the location where the looseness occurs and optimize it, and there is no need to pay attention to defects during software optimization.

[0047] Specifically, adequate pouring can reduce the risk of casting defects such as porosity, looseness and slag inclusions, because the casting can fill all the gaps in the mold and avoid the mixing of air or slag inclusions. It is a crucial step in the casting process, which helps us eliminate the problems caused by insufficient pouring and find problems in the test process more quickly.

[0048] In one embodiment, in step 103, three-dimensional dimensions and relative position accuracy tests are performed on the tenon 101, the extended root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106, typical structures of the test casting, to obtain the corresponding spatial dimensions and position accuracy, and then the structural characteristic shrinkage rate and relative position torsional offset of the tenon 101, the extended root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 are calculated.

[0049] Specifically, during the test process, after the blades are successfully produced using the test mold, it is necessary to make precise measurements of the size, dimensions, position, etc. of the blades in order to produce high-precision blades.

[0050] Furthermore, shrinkage and relative position torsional offset are key parameters used to control and adjust the size and position of parts to ensure that the final product meets the design requirements.

[0051] In one embodiment, in step S104, according to the structural characteristic shrinkage rate and relative position torsion offset of the tenon 101, the extension root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 calculated in step S103, correction tests and reverse deformation tests are performed on the characteristic structures to complete the design of the formal wax model size.

[0052] Specifically, the correction test is mainly used to solve size and shape problems, while the reverse deformation test is mainly used to verify the performance and reliability of the product. Both methods play an important role in different stages and applications, helping manufacturers and engineers improve product quality, reduce costs and detect problems in advance.

[0053] In one embodiment, in step S105, the formal mold design includes the size design, cotton packing design and mold shell design of multiple formal wax molds and the center injection pipe 22, the base 23, the runner plate 24, the runner assembly 25 and the blind riser 26.

[0054] In one embodiment, in step S105, the dimensions of the center injection pipe 22, the base 23, the runner plate 24 and the runner assembly 25 are determined based on experience and simulation software, and the elongation of the T-shaped area of ​​the T-shaped blind riser 26 relative to the blade crown 105 is designed based on twice the recrystallization or fracture position of the blade body in step S103, or other suitable dimensions.

[0055] Specifically, the cast metal shrinks when it cools and solidifies. This shrinkage can cause internal stresses, especially in thin-walled parts or parts with uneven thickness of the casting. These stresses may cause cracks or shape changes. A T-shaped blind riser 26 is installed on the blade crown 105 of the blade. The T-shaped blind riser 26 is a channel connecting the wax model to the wax model gate. It ensures that the molten wax can flow evenly into the entire model and fill each part to avoid the formation of gaps or bubbles. By designing the size and shape of the T-shaped blind riser 26, the speed of the molten wax inflow can be controlled to ensure that the model is fully filled while avoiding excessive waste of molten wax. The T-shaped blind riser 26 can also be used to exhaust air or bubbles in the model to avoid defects or uneven results during the casting process. In the present embodiment, the T-shaped blind riser 26 is connected to the gate of the runner assembly 25, and the gate is where the liquid metal is cast into the model. This ensures that the metal can flow smoothly into the entire model and fill the cavity in the model.

[0056] In one embodiment, in step S106, iterative optimization includes: iteratively optimizing the wax mold shell and cotton packing design, continuously adjusting casting parameters and shell preheating parameters, and finally obtaining a low-vortex working blade casting whose metallurgical dimensions meet the drawing and material standards.

[0057] Specifically, by adjusting the casting parameters and the mold shell preheating parameters, the casting process can be improved, the product quality can be improved, the cost can be reduced, the scrap rate can be reduced, and the process stability can be improved.

[0058] Specifically, during the test process, it is usually more economical to use one mold shell relative to multiple mold shells, because only one mold shell needs to be manufactured and maintained, and it is easier to manage. Moreover, the operation of one mold shell is relatively simple, because only one mold shell needs to be handled, and there is no need to consider the coordination between the two mold shells. Finally, using one mold shell can load and unload more quickly, thereby improving production efficiency. In the production process, the use of multiple mold shells can achieve higher production efficiency, because while testing in one mold shell, another mold shell can be prepared, thereby reducing downtime. Moreover, the use of multiple mold shells can shorten the test and production cycle, because one mold shell can continue to operate during loading and unloading. Multiple mold shells allow continuous operation, thereby realizing continuous production and testing, which is particularly suitable for applications requiring high output. Finally, multiple mold shells provide redundancy. If one mold shell fails or needs maintenance, another mold shell can still continue to operate, thereby reducing production interruptions.

[0059] Specific test steps:

[0060] Step S101, design of the test wax mold 10 of the casting method of the low-vortex working blade. According to the shrinkage rate of zero, the dimensions of the tenon 101, the extension root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 are designed, and the test wax mold 10 of the low-vortex working blade is processed by milling. The wax mold material used at this time is consistent with the material used for the formal wax mold 11 in the later stage. The dimensions of the designed test wax mold 10 need to be recorded in actual dimensions under blue light or three-dimensional coordinates.

[0061] Step S102, design of the test module for the casting method of the low-vortex working blade. The test module of a single low-vortex working blade includes a test wax mold 10, a pouring cup 21, a center pouring pipe 22, a base 23, a pouring plate 24 and a pouring assembly 25, wherein the dimensions of the pouring cup 21, the center pouring pipe 22, the base 23, the pouring plate 24 and the pouring assembly 25 can be simulated in casting simulation software such as Procast. During the simulation process, it is necessary to ensure that the location where the looseness occurs is recorded when the pouring is sufficient, but there is no need to pay attention to the defects of the wax mold at this stage.

[0062] Step S103, test wax mold shell casting and casting size measurement of the casting method of the low-vortex working blade. After completing the test module design in step 102, the test wax mold 10 is wrapped with a shell material to form an external mold shell. The mold shell and the pouring mechanism are assembled to form a test mold so that casting can be performed in the subsequent process, and the test casting is cast. Then, the structure of the test casting, such as the tenon 101, the extended root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106, is measured in three dimensions and relative position to obtain the corresponding spatial dimensions and position, and then the structural characteristic shrinkage and relative position torsion offset of the tenon 101, the extended root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 are calculated.

[0063] Step S104, design of the formal wax model 11 of the casting method of the low-vortex working blade. According to the three-dimensional shrinkage and relative position torsion offset of the tenon 101, the extended root 102, the edge plate 103, the blade body 104, the blade crown 105 and the blade sealing tooth 106 structure characteristics obtained in step S103, the characteristic structure is corrected and reversed to complete the size design of the formal wax model 11.

[0064] Step S105, design of the formal mold set for the casting method of the low-vortex working blade. Complete the size design, cotton packing design and mold shell design of the formal wax mold 11, the center injection pipe 22, the base 23, the runner plate 24, the runner assembly 25 and the T-shaped blind riser 26. The size of the center injection pipe 22, the base 23, the runner plate 24 and the runner assembly 25 can be set based on experience and simulation software. The blind riser 26 is installed on the formal wax mold 11. The elongation of the T-shaped area of ​​the T-shaped blind riser 26 relative to the blade crown 105 is designed to be twice the recrystallization or fracture position of the blade body 104 in step S103, and can also be designed according to other suitable sizes.

[0065] Step S106, the casting method of the low-vortex working blade is to perform the formal wax mold shell casting and iterative optimization of casting parameters. After the formal module design is completed in step S105, the formal wax mold 10 is wrapped with a shell material to form an external mold shell, and the mold shell and the pouring mechanism are assembled to form a formal mold. The obtained formal mold is used for pouring, and the casting parameters and the mold shell preheating parameters are continuously adjusted, and iterative optimization is continuously performed to finally obtain a blade casting that meets the drawing and material standards.

[0066] Specifically, the batt design can choose to add insulating material, usually asbestos or ceramic fiber wool, into the mold to isolate the mold shell and the mold, prevent excessive heat transfer and protect the mold surface from high temperature corrosion.

[0067] The present invention has the following beneficial effects:

[0068] 1. Wax block machining blade structure optimization method: The present invention proposes a wax block structure optimization method for machining blades. This method aims to quickly obtain the three-dimensional structure and characteristics of the blade while taking into account the shrinkage problem. By placing the shrinkage according to different structural features, the size and shape of the casting can be better controlled, which helps to improve mold preparation and casting size control.

[0069] 2. Innovation in T-shaped blind riser design: The present invention proposes an innovative blind riser design method to solve the problem of loose blade crown. This method not only helps to reduce the looseness of the blade crown, but also improves the rigidity of the blade near the blade crown by designing a "T-shaped" blind riser. This helps to improve the deformation coordination between the blade crown and the blade, reduce the stress concentration in specific areas of the blade, and thus reduce the stress of the blade.

[0070] 3. Applicable to the casting of low-vortex blades of aircraft engines: The low-vortex blade casting scheme proposed by the present invention is applicable to the casting of low-vortex working blades of aircraft engines. This scheme has high consistency and is expected to have a wide range of application prospects in the aviation field because it can improve the quality, performance and production efficiency of castings.

[0071] In the description of the present application, it should be noted that the terms used herein are only for describing specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. For ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be regarded as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary, rather than as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0072] It should be noted that, in the present application, "tenon" refers to the root connection part of the blade, and "extended root" is adjacent to the tenon, which is used to connect and fix the blade. In the present application, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements that are not explicitly listed, or also includes elements inherent to such process, method, article or device. It should also be pointed out that the scope of the method and device in the embodiments of the present application is not limited to performing functions in the order shown or discussed, and may also include performing functions in a substantially simultaneous manner or in reverse order according to the functions involved. For example, the described method may be performed in an order different from that described, and various steps may also be added, omitted, or combined. In addition, the features described with reference to certain examples may be combined in other examples.

[0073] In addition, it should be noted that, unless otherwise clearly specified and limited, words such as "connect" and "drive" used in the description of this application should be understood in a broad sense, which can be direct, through an intermediate medium, or the relationship between two elements. Technical personnel in the field can understand their specific meanings in this application based on the specific circumstances.

[0074] The above embodiments are provided for persons familiar with the art to implement or use the present application. Personnel familiar with the art can make various modifications or changes to the above embodiments without departing from the application concept of the present application. Therefore, the protection scope of the present application is not limited to the above embodiments, but should be the maximum scope of the innovative features mentioned in the claims.

Claims

1. A method for casting a low-vortex working blade, characterized in that: The casting method of the low vortex working blade comprises: Step S101, designing a test wax mold, designing the shape, size and contour of the test wax mold according to the shape, size and contour of the required blade, and making a test wax mold that matches the required blade by milling; Step S102, test module design, assembling the single test wax mold designed in step S101 and the casting mechanism into a test module, designing the size of the casting mechanism, and simulating and optimizing it on the software; Step S103, test wax mold shell, and perform test casting together with the test module. After the casting is completed, obtain the test casting, perform three-dimensional size and relative position test on the typical structure of the test casting, obtain spatial size and position data, and calculate the structural characteristic shrinkage rate and relative position torsion offset; Step S104, formal wax model design, correction and anti-deformation test are performed according to the result of step S103 to complete the shape, size and contour design of the formal wax model; Step S105, formal module design, combining multiple formal wax molds and a casting mechanism, designing the size, cotton packing and mold shell of the casting mechanism, the casting mechanism includes a T-shaped blind riser to improve the rigidity of the blade; Step S106, formal wax mold shell, formal casting and iterative optimization together with the formal mold set, constantly adjusting the casting parameters until a low-vortex working blade casting that meets the size and material standards is obtained.

2. The casting method of low vortex working blade according to claim 1, characterized in that: In step S101, the wax model includes a tenon, an extension root, a lip plate, a blade body, a blade shroud and a blade sealing tooth, and the dimensions of the tenon, the extension root, the lip plate, the blade body, the blade shroud and the blade sealing tooth are extracted when the shrinkage rate is zero.

3. The casting method of low vortex working blade according to claim 2, characterized in that: In step S101, the test wax model is made of the same material as the formal wax model, and the dimensions of the tenon, the extension root, the edge plate, the blade body, the blade crown and the blade sealing tooth under blue light or three-dimensional coordinates are recorded.

4. The casting method of low vortex working blades according to claim 3, characterized in that: In step S102, the test module design includes the size design of a single test wax mold and a pouring mechanism, and the pouring mechanism includes a pouring cup, a center pouring tube, a base, a pouring plate and a pouring runner assembly.

5. The casting method of low vortex working blades according to claim 4, characterized in that: In step S102, the parameters of the pouring tube, base, pouring plate and pouring runner combination size are simulated using Procast casting software to ensure sufficient pouring, record the location where the looseness occurs and optimize it, and do not pay attention to defects during software simulation.

6. The casting method of low vortex working blades according to claim 4, characterized in that: In step S103, the three-dimensional dimensions and relative position of the typical structures of the test casting, such as the tenon, the extension root, the edge plate, the blade body, the blade crown and the blade sealing tooth, are tested to obtain the corresponding spatial dimensions and position, and then the structural characteristic shrinkage rate and the relative position torsional offset of the tenon, the extension root, the edge plate, the blade body, the blade crown and the blade sealing tooth are calculated.

7. The casting method of low vortex working blades according to claim 6, characterized in that: In step S104, according to the characteristic shrinkage rate and relative position torsion offset of the tenon, root extension, edge plate, blade body, blade crown and blade sealing tooth structure calculated in step S103, the characteristic structure is corrected and reversely deformed to complete the design of the formal wax model size.

8. The casting method of low vortex working blades according to claim 4, characterized in that: In step S105, the formal module design includes the size design of multiple formal wax molds and the center injection tube, base, runner plate, runner assembly and T-shaped blind riser, cotton packing design and mold shell design.

9. The casting method of low vortex working blades according to claim 8, characterized in that: In step S105, the dimensions of the center injection pipe, base, runner plate and runner assembly are determined based on experience and simulation software, and the elongation of the T-shaped area of ​​the T-shaped blind riser relative to the blade crown is designed to be twice the recrystallization or fracture position of the blade body in step S103.

10. The casting method of low vortex working blades according to claim 8, characterized in that: In step S106, iterative optimization includes: iteratively optimizing the wax mold shell and cotton packing design, continuously adjusting the casting parameters and shell preheating parameters, and finally obtaining a low-vortex working blade casting whose metallurgical dimensions meet the drawing and material standards.

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