Aerospace blade casting and de-molding process
By integrating clamping vibration, ultrasonic vibration and hot air drying into a composite demolding device, the problem of the cumbersome demolding process after casting aero-blades has been solved, achieving efficient connection between casting and demolding, and improving production efficiency and equipment lifespan.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHANGHAI WANZE PRECISION CASTING CO LTD
- Filing Date
- 2026-05-22
- Publication Date
- 2026-08-04
AI Technical Summary
The current demolding process for aircraft blades after casting relies on manual operation, which is cumbersome and labor-intensive, making it difficult to meet the needs of mass production.
The composite demolding equipment integrates clamping vibration, ultrasonic vibration and hot air drying functions, and is combined with multiple blade forming cavities that are integrally formed and arranged in a straight line to achieve efficient connection between the casting and demolding processes.
It significantly improves demolding efficiency, reduces the labor intensity of operators, simplifies the operation process, and increases mass production capacity.
Smart Images
Figure CN122231241B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of metal casting and demolding, and in particular to the casting and demolding of aircraft blades. Background Technology
[0002] Aircraft blades are crucial components of aero engines, and they are typically manufactured using a casting process. The process involves first creating a wax model of the blade, then using this model to create a casting mold with the blade's forming cavity. Molten metal is then poured into the cavity of the casting mold. After the metal cools and solidifies, the casting mold covering the blade is removed through a demolding process. Finally, the riser is removed, yielding the finished blade.
[0003] Currently, the demolding of aircraft blades after casting is mainly done manually. Operators typically perform rough demolding first, using hammering tools to separate the casting mold from the blade surface. After rough demolding, fine demolding is performed, where operators repeatedly wash the blade surface with a high-pressure water gun to remove casting mold debris remaining on the blade's complex curved surface. This is supplemented by manual hammering to completely remove the casting mold. This entire process is extremely cumbersome. Operators not only have to endure the physical exhaustion from repeated hammering for extended periods, but also frequently handle, soak, and wash the blades, resulting in extremely high labor intensity. This leads to low efficiency in blade casting and demolding, making it difficult to meet the needs of mass production. Summary of the Invention
[0004] In view of the shortcomings of the existing technology, one of the objectives of this invention is to provide a casting and demolding process for aircraft blades.
[0005] The aircraft blade casting and demolding process provided in this application adopts the following technical solution: The process of casting and demolding aircraft blades involves setting up blade forming cavities in the casting mold. The casting mold is made in one piece and has at least 6 blade forming cavities arranged in a straight line. Cast the blades, and after the blades cool, clean out the blade risers; The demolding process uses a composite demolding device: The composite demolding equipment includes a worktable, a clamping vibration system, an ultrasonic vibration system, and a drying system; The worktable surface is higher than the blade length; The workbench is equipped with at least 6 clamping vibration systems; The clamping vibration system includes a clamp and a vibrator; The clamp has a jaw for holding the blade riser, with the top of the blade riser protruding outside the jaw; A buffer structure is provided on one side of the clamp; The vibrator is located on the other side of the clamp and opposite to the buffer structure. The range of motion of the vibrating end of the vibrator covers the area above the clamp. The ultrasonic vibration system includes a tubular container suspended below the platform to house the blades, with an openable plug at the lower end of the tubular container. The ultrasonic generator of the ultrasonic vibration system is located on the plug. After the plug is closed, the ultrasonic generator is encapsulated in a tubular container. The drying system has hot air inlets; The tubular container has at least four air vents arranged in a ring at the top, and the hot air vent is connected to the at least four air vents; The demolding process steps are as follows: a: Use a clamp to hold the blade riser and tap the casting mold to expose the blade; b: Assemble a tubular container, with blades extending into the tubular container; c: Open the plug and start the vibrator to apply vibration to the riser; d: Turn off the vibrator and plug, fill the tubular container with water until the blades are submerged, and start the ultrasonic generator to vibrate; e: Turn off the ultrasonic generator, open the plug, and blow hot air into the air vent; f: Open the plug, apply vibration to the riser again, and repeat steps c~f after the vibration ends; g: After the blades are demolded, cut off the portion of the blade riser that is exposed above the clamp.
[0006] This application provides a casting and demolding process for aerospace blades. By integrating clamping vibration, ultrasonic vibration, and hot air drying into a single composite demolding device, and using a casting mold with at least six blade forming cavities arranged in a straight line, a highly efficient connection from casting to demolding is achieved. Specifically, after casting, the operator only needs to tap the casting mold to separate the blade from the mold body and expose the blade. Then, the blade riser is held by a clamp and suspended in a tubular container, and vibration demolding, ultrasonic fine demolding, hot air drying, and re-vibration demolding are completed sequentially. Throughout the process, the blade does not need to be frequently moved to different work stations, the operator does not need to endure the physical exertion of long-term manual tapping, and there is no need to repeatedly handle, soak, and rinse the blade, thus significantly improving demolding efficiency and reducing labor intensity.
[0007] This application does not simply superimpose multiple demolding methods, but rather coordinates each step to create favorable conditions for subsequent operations. The blade riser is removed from the casting mold and held in place by a clamp. A preliminary rough demolding is then performed on the blade, separating the casting mold from the blade. Subsequently, a tubular container is assembled, and the blade is inserted into the container to prepare for fine demolding. During fine demolding, the plug is opened, and a vibrator is used to apply vibration to the blade riser, creating micro-cracks in the stubborn residual mold. Then, ultrasonic vibration is used to generate cavitation in a liquid environment, peeling off the loosened but still attached mold debris from the blade surface. After ultrasonic treatment, residual moisture on the blade surface can leave trace amounts of mold debris in a damp, adherent state. Direct re-vibration will have minimal demolding effect. To address this issue, this application introduces hot air drying after the ultrasonic step. The purpose is not only to dry the blade but, more importantly, to dry and brittle the remaining mold debris, allowing for complete removal of the mold debris with lower vibration energy during subsequent vibration. After demolding, mold residue remains. By repeating cycles of ultrasonic waves, drying, and vibration, all casting mold residue can be gradually removed until the blade is completely demolded. Finally, the riser portion exposed above the clamp is cut off to obtain the finished blade.
[0008] For composite demolding equipment, this application features a special design for the clamping path of the tubular container and fixtures. The bottom of the tubular container uses an openable plug, which remains open during the vibration phase to allow the dislodged mold debris to be directly discharged, preventing debris accumulation from interfering with subsequent operations. During the ultrasonic vibration phase, the plug closes to allow the tubular container to store water. During the drying phase, it reopens to create a hot air outlet channel, achieving dehumidification. A single plug, through a simple opening and closing action, collaboratively performs multiple functions including chip removal, water storage, drainage, and air circulation, thus simplifying equipment operation. A buffer structure on one side of the clamp absorbs the impact energy transmitted by the vibrator during both vibration cycles, protecting the fixture's drive components from damage. Simultaneously, during ultrasonic vibration, it absorbs the transmission of micro-vibrations to the fixture's drive components. This reduces the cumulative damage to the fixture's drive components from vibration over long-term use, thereby extending the equipment's service life.
[0009] Furthermore, this application employs a casting mold with at least six blade forming cavities arranged in a straight line, which allows multiple blades to be obtained simultaneously in a single casting. Combined with at least six clamping vibration systems on the equipment, it can handle the demolding of multiple blades in parallel. After the molten metal is cast, the six blade forming cavities are connected together above the riser. When the riser is clamped by a jig, the casting part connected above each blade riser can assist the jig in fixing each blade, thereby improving assembly efficiency. When each vibrator applies vibration to the blade riser, the vibration applied by each vibrator to the blade riser can also be transmitted from the casting connection part above the blade riser, thereby assisting in the demolding of the blades.
[0010] Preferably, the buffer structure includes a rubber buffer layer and a polyurethane buffer layer stacked together.
[0011] During vibration demolding, vibration will inevitably be transmitted to the drive components of the fixture. Especially after repeated vibrations, frequent vibrations will cause the drive components of the fixture to age or fail, thus seriously affecting the life of the equipment.
[0012] The buffer structure uses a combination of rubber and polyurethane buffer layers. The rubber buffer layer has a high elastic deformation capacity, which can efficiently absorb the impact generated by the vibrator and reduce the peak impact force transmitted to the drive components of the clamp. The polyurethane buffer layer, with its wear resistance and elasticity, maintains dimensional stability during repeated compression and rebound, avoiding indentations or permanent deformation caused by long-term impact.
[0013] Preferably, the workbench is provided with U-shaped channel steel with the slot opening facing upwards, and the number of U-shaped channel steel is matched with the number of clamping vibration systems; The workbench and the U-shaped channel steel have an opening that allows the workbench and the U-shaped channel steel to pass through each other vertically. The clamp is disposed inside the U-shaped channel steel, and the clamping jaw of the clamp is located above the opening.
[0014] This application utilizes the two side walls of the U-shaped channel steel to intercept the splash residue generated during the vibration chip removal process inside the U-shaped channel steel, forcing the splash residue to fall only along the opening to the bottom of the workbench, thereby ensuring that the workstation can remain clean for a long time, thus eliminating the need for operators to clean frequently and reducing the labor of operators.
[0015] Preferably, the clamp includes a stroke-adjustable cylinder, a positioning block, and two clamping blocks; The cylinder's telescopic end is provided with the buffer structure; One clamping block is disposed on the buffer structure, and the other clamping block is disposed on the positioning block; The clamp is located between the two clamping blocks.
[0016] Operators can adjust the stroke parameters of the cylinder to ensure that the two clamping blocks fit the sides of the riser with appropriate pressure. This prevents the riser from being clamped too tightly, which would cause stress to be transmitted to the blades, and also prevents relative slippage from occurring due to being too loose, thus maintaining a stable clamping force.
[0017] Preferably, the control switch for the cylinder of the clamping vibration system is located on the worktable.
[0018] By adopting the above technical solution, the switches of each independent unit are brought together, allowing operators to complete the clamping and releasing actions of all workstations from one position. This enables centralized control during the batch demolding of aircraft blades, thereby improving the demolding efficiency of batch demolding operations.
[0019] Preferably, the clamp is covered with a protective pad.
[0020] When the vibrating end of the vibrator deviates from the target due to external force and vibrates and strikes the clamp, the protective pad can protect the clamp from direct impact and damage, avoiding damage to the clamp caused by accidental impact.
[0021] Preferably, at least 6 vibrators 2 vibrate at staggered vibration frequencies.
[0022] By staggering the vibration frequencies of at least six vibrators, resonance is effectively avoided when multiple vibrators work simultaneously, the concentrated superposition of vibration energy at a single frequency is eliminated, and the impact damage of resonance to the fixture is prevented.
[0023] Preferably, the vibrating ends of the vibrators in two adjacent clamping vibration systems are arranged opposite each other.
[0024] By arranging the vibrating ends of the vibrators in adjacent clamping vibration systems relative to each other, a staggered arrangement of the vibrators and buffer structures is formed in the arrangement direction of the clamping vibration systems. This disperses the vibrators on the worktable, increases the physical distance between adjacent vibration sources, weakens the vibration coupling between workstations, and prevents resonance from causing impact damage to the fixture.
[0025] Preferably, after the blade extends into the tubular container, there is a gap between the blade and the inner wall of the tubular container, with the gap spacing being 3~8mm.
[0026] A gap of 3-8mm ensures smooth suspension and movement of the blades within the container while preventing friction or jamming between the blades and the container wall due to excessively small gaps. Simultaneously, the 3-8mm gap allows for sufficient water to be held during the ultrasonic vibration step, ensuring the ultrasonic cavitation effect fully engages the blade surface. Furthermore, it prevents low drying efficiency caused by excessively large gaps during the blade drying process.
[0027] In summary, this application includes at least one of the following beneficial technical effects: 1. This application provides a casting and demolding process for aircraft blades. By integrating clamping vibration, ultrasonic vibration, and hot air drying into the same composite demolding equipment, and using a casting mold with at least six blade forming cavities arranged in a straight line, a highly efficient connection from casting to demolding is achieved. Specifically, after casting, the operator only needs to tap the casting mold to separate the blade from the mold body and expose the blade. Then, the blade riser is clamped by a clamp to suspend the blade in a tubular container, and vibration demolding, ultrasonic fine demolding, hot air drying, and re-vibration demolding are completed sequentially. Throughout the process, the blade does not need to be frequently moved to different work stations, the operator does not need to endure the physical exertion of long-term manual tapping, and there is no need to repeatedly handle, soak, and wash the blade, thereby significantly improving demolding efficiency and reducing labor intensity. 2. This application does not simply superimpose multiple demolding methods, but rather coordinates each step to create favorable conditions for subsequent operations. The blade riser is removed from the casting mold and held in place by a clamp. A preliminary rough demolding is then performed on the blade, separating the casting mold from the blade. Subsequently, a tubular container is assembled, and the blade is inserted into the container to prepare for fine demolding. During fine demolding, the plug is opened, and a vibrator is used to apply vibration to the blade riser, causing micro-cracks in the stubborn mold residue. Then, ultrasonic vibration is used to generate cavitation in a liquid environment, peeling off the loosened but still attached mold debris from the blade surface. After ultrasonic treatment, residual moisture on the blade surface will leave a small amount of mold debris in a damp, adherent state. Direct re-vibration will have minimal demolding effect. To address this issue, this application introduces hot air drying after the ultrasonic step. The purpose is not only to dry the blade, but more importantly, to dry and brittle the remaining mold debris, allowing for thorough removal of the mold debris with lower vibration energy during re-vibration. After demolding, mold residue remains. By repeating cycles of ultrasonic waves, drying, and vibration, all casting mold residue can be gradually removed until the blade is completely demolded. Finally, the riser portion exposed above the clamping opening is cut off to obtain the finished blade. 3. This application features a special design for the clamping path of the tubular container and fixture in the composite demolding equipment. The bottom of the tubular container uses an openable plug. The plug remains open during the vibration step, allowing the dislodged mold debris to be directly discharged, preventing debris accumulation from interfering with subsequent operations. It closes during the ultrasonic vibration step, allowing the tubular container to store water. It reopens during the drying step, forming a hot air outlet channel for dehumidification. A single plug, through a simple opening and closing action, collaboratively performs multiple functions: debris removal, water storage, drainage, and air circulation, thus simplifying equipment operation. A buffer structure on one side of the clamp absorbs the impact energy transmitted by the vibrator during both vibration cycles, protecting the fixture's drive components from damage. Simultaneously, during ultrasonic vibration, it absorbs the transmission of micro-vibrations to the fixture's drive components. This reduces the cumulative damage to the fixture's drive components from vibration over long-term use, thereby extending the equipment's service life. Attached Figure Description
[0028] Figure 1 This embodiment of the application is a schematic diagram illustrating the structure of a composite demolding device; Figure 2 This embodiment of the application is a schematic diagram illustrating the structure of a tubular container; Figure 3 This is a schematic diagram illustrating the structure of the cylinder, positioning block, and clamping block in an embodiment of this application.
[0029] Reference numerals: 1. Workbench; 2. Vibrator; 3. Buffer structure; 4. Tubular container; 5. Plug; 6. Air outlet; 7. U-shaped channel steel; 8. Cylinder; 9. Positioning block; 10. Clamping block. Detailed Implementation
[0030] The following is in conjunction with the appendix Figure 1 -Appendix Figure 3 This application will be described in further detail.
[0031] This application discloses the casting and demolding process for aircraft blades.
[0032] Reference Figure 1 and Figure 2 The process of casting and demolding aircraft blades involves setting up blade forming cavities in a casting mold. The casting mold is made of one piece and has at least six blade forming cavities arranged in a straight line side by side. After casting the blades and allowing them to cool, the blade risers are removed.
[0033] The demolding process uses a composite demolding device: The composite demolding equipment includes a worktable 1, a clamping vibration system, an ultrasonic vibration system, and a drying system. The worktable 1 has a surface higher than the blade length. At least six clamping vibration systems are installed on the worktable 1, each including a clamp and a vibrator 2. The clamp has a jaw for holding the blade riser, with the blade riser protruding above the jaw. A buffer structure 3 is provided on one side of the jaw, and the vibrator 2 is located on the other side of the jaw, opposite to the buffer structure 3. The vibrating end of the vibrator 2 covers the area above the jaw.
[0034] The ultrasonic vibration system includes a tubular container 4 suspended below the table to house the blades, with an openable plug 5 at the lower end of the tubular container 4. The ultrasonic generator of the ultrasonic vibration system is mounted on the plug 5; when the plug 5 is closed, the ultrasonic generator is enclosed within the tubular container 4. The drying system has hot air vents. At least four air vents 6 are arranged in a ring on the upper part of the tubular container 4, and the hot air vents are connected to the at least four air vents 6.
[0035] The demolding process steps are as follows: a: Use a clamp to hold the blade riser and tap the casting mold to expose the blade; b: Assemble the tubular container 4, with the blades extending into the tubular container 4; c: Open plug 5 and start vibrator 2 to apply vibration to the riser; d: Turn off vibrator 2 and plug 5, fill tubular container 4 with water until the blades are submerged, and start ultrasonic generator to vibrate; e: Turn off the ultrasonic generator, open the plug 5, and introduce hot air into the air outlet 6; f: Open plug 5, apply vibration to riser again, and repeat steps c~f after stopping vibration; g: After the blades are demolded, cut off the portion of the blade riser that is exposed above the clamp.
[0036] Specifically, the blade casting uses a casting mold made from a wax model. The casting mold has at least six blade forming cavities, and the arrangement of the blade forming cavities corresponds one-to-one with the arrangement spacing and position of the clamping vibration system. That is, at least six blade forming cavities are arranged in a straight line side by side. The blade forming cavities have a connected casting channel at the upper position. When casting blades using the casting mold, molten metal only needs to be poured from one gate to cast at least six blades connected above the blade riser. That is, the molten metal is cooled after passing through the casting channel above the blade riser to form a casting connector located above the blade riser that connects at least six blades.
[0037] After casting, the blade risers are cleaned out. When using a jig to hold the blade risers, the casting connectors connected above each blade riser can help the jig fix each blade, thereby improving assembly efficiency.
[0038] For composite demolding equipment: The height of the workbench 1 is greater than the length of the aircraft blade, so that when the aircraft blade is clamped, the blade part can hang naturally below the workbench 1, and the casting mold debris shaken off will fall off automatically by gravity, avoiding the accumulation of residue on the workbench 1.
[0039] A clamp is used to hold the riser of an aircraft blade, and a vibrator 2 is used to apply vibration to the riser of the aircraft blade. The clamp has a jaw consisting of two opposing clamping surfaces with shapes that match the riser. The thickness direction of the jaw is consistent with the length direction of the aircraft blade after it is clamped; that is, the thickness of the jaw refers to its vertical height. The thickness of the jaw is designed to be less than the length of the riser of the aircraft blade. When the riser of the aircraft blade is placed in the jaw, because the thickness of the jaw is less than the length of the riser, a portion of the riser will protrude above the jaw.
[0040] The buffer structure 3 is installed on the clamping force transmission path of the fixture, that is, the buffer structure 3 is located between the driving component of the fixture and the clamping surface. The vibrating end of the vibrator 2 is located on the other side of the clamp, and the vibrating end of the vibrator 2 is opposite to the position of the buffer structure 3. That is, the buffer structure 3 and the driving component of the fixture are located on one side of the clamp, and the vibrating end of the vibrator 2 is located on the other side. In this embodiment, the vibrator 2 is mounted on the workbench 1 by a bracket, and the range of motion of the vibrating end of the vibrator 2 is set to cover the top of the clamp, that is, when the riser of the aircraft blade is clamped in the clamp and the part of the riser protruding above the clamp is covered by the vibrating end, the vibrating end can extend into the space above the clamp and contact the riser.
[0041] The ultrasonic vibration system includes a tubular container 4 and an ultrasonic generator. The tubular container 4 is detachably suspended below the table surface of the workbench 1 and corresponds one-to-one with each clamping vibration system. The tubular container 4 is a vertically arranged cylindrical structure with an inner diameter slightly larger than the maximum width of the aircraft blade. When the aircraft blade extends into the tubular container 4 from above, a gap of 3-8 mm is maintained between the blade and the inner wall of the tubular container 4 to avoid contact with the inner wall. During the ultrasonic vibration step, the 3-8 mm gap can also hold sufficient water to ensure that the ultrasonic cavitation effect is fully applied to the blade surface. In addition, during the blade drying step, it can also prevent low drying efficiency due to excessive gap.
[0042] A water inlet is provided at the upper part of the tubular container 4, and an openable plug 5 is provided at the lower end of the tubular container 4. The ultrasonic generator is fixedly installed inside the plug 5. When the plug 5 is closed, the ultrasonic generator is enclosed inside the lower end of the tubular container 4. When the plug 5 is opened, the ultrasonic generator moves out of the lower end of the tubular container 4 along with the plug 5, thereby avoiding damage during vibration chip removal, drainage, or drying ventilation.
[0043] The drying system includes a hot air blower and an air outlet duct. The hot air outlet of the hot air blower is connected to at least four air inlets 6 surrounding the upper part of the tubular container 4 via the air outlet duct. When the hot air blower is operating, hot air is blown out through the annularly arranged air inlets 6, forming an airflow around the blades inside the tubular container 4. When the bottom plug 5 is open, the hot air flows from top to bottom across the blade surface and is smoothly discharged from the bottom plug 5, forming a drying airflow path.
[0044] For the demolding process: a: Use a clamp to hold the blade riser and tap the casting mold to expose the blade.
[0045] After the blade is cast and cooled, and the operator removes the riser from the blade, the operator places the blade into the clamping jaws of the fixture with the riser facing upwards, so that the riser is positioned between the two clamping surfaces and a portion of the riser protrudes above the clamping jaws. At the same time, the operator uses a tapping method to knock the blade body open from the casting mold to expose the blade, thus achieving preliminary rough demolding.
[0046] b: Assemble the tubular container 4, with the blades extending into the tubular container 4.
[0047] After the blades are exposed, the tubular container 4 is assembled under the workbench 1 so that the blades extend into the tubular container 4.
[0048] c: Open plug 5 and start vibrator 2 to apply vibration to the riser.
[0049] Open the plug 5 at the lower end of the tubular container 4, start the vibrator 2, and repeatedly tap the riser with the vibrating end of the vibrator 2.
[0050] During vibration, large, loose pieces of demolding residue adhering to the blade surface are detached due to the vibration and fall under the influence of gravity. Since the plug 5 has been opened, these shaken-off residues are discharged directly from the bottom of the tubular container 4.
[0051] d: Turn off vibrator 2 and plug 5, fill tubular container 4 with water until the blades are submerged, and start ultrasonic generator to vibrate.
[0052] After the initial vibration is complete, the vibrator 2 is turned off. The plug 5 is closed, and water is then poured into the tubular container 4 until the entire length of the blade is submerged. The ultrasonic generator is then activated, and the ultrasonic energy creates a cavitation effect near the blade surface, forming a large number of tiny bubbles. When the bubbles burst, they peel off and break up the stubborn deposits remaining on the blade surface.
[0053] e: Turn off the ultrasonic generator, open the plug 5, and introduce hot air into the air outlet 6.
[0054] After the ultrasonic vibration ends, turn off the ultrasonic generator. Open the plug 5 again, and the water in the tubular container 4, along with the mold debris, will be discharged. Then, start the drying system. The hot air blower generates hot air, which is blown out from at least four annularly arranged air vents 6, forming a surrounding hot airflow around the blades and discharged from the bottom plug 5 until the blade surface is completely dry.
[0055] f: Open plug 5, apply vibration to the riser again, and repeat steps c~f after the vibration ends.
[0056] After drying, keep plug 5 open. Restart vibrator 2 to apply vibration to the riser. At this point, the surface of the aircraft blade is completely dry, and the remaining mold residue has lost moisture and become brittle. The re-vibration of vibrator 2 can easily peel off these brittle residues, thus obtaining a clean and dry aircraft blade. If residues remain after cleaning, repeat steps c to f.
[0057] g: After the blades are demolded, cut off the portion of the blade riser that is exposed above the clamp.
[0058] After the blades are demolded, the operator uses a cutting tool to remove the riser that protrudes above the clamping opening, thereby removing the riser that protrudes above the clamping opening and the casting connector that connects at least 6 blades, thus obtaining an individual blade.
[0059] This application provides a casting and demolding process for aerospace blades. By integrating clamping vibration, ultrasonic vibration, and hot air drying into the same composite demolding equipment, and using a casting mold with at least six blade forming cavities arranged in a straight line, a highly efficient connection from casting to demolding is achieved. Throughout the entire process of blade casting and demolding, the blades do not need to be frequently moved between workstations, operators do not need to endure the physical exertion of prolonged manual hammering, and there is no need to repeatedly handle, soak, and rinse the blades, thereby significantly improving demolding efficiency and reducing labor intensity.
[0060] Furthermore, the tubular container 4 of this application employs an openable plug 5 at its bottom. The plug 5 remains open during the vibration step, allowing the dislodged mold debris to be directly discharged, preventing debris accumulation from interfering with subsequent operations. It closes during the ultrasonic vibration step, allowing the tubular container 4 to store water. During the drying step, it reopens, forming a hot air outlet channel for dehumidification. A single plug 5, through a simple opening and closing action, collaboratively performs multiple functions including debris removal, water storage, drainage, and air circulation, thus simplifying equipment operation. The buffer structure 3 located on one side of the clamp absorbs the impact energy transmitted by the vibrator 2 during both vibration cycles, protecting the clamp's drive components from damage. Simultaneously, during ultrasonic vibration, it absorbs the transmission of micro-vibrations to the clamp's drive components. This reduces the cumulative damage to the clamp's drive components from vibration during long-term use, thereby extending the equipment's service life.
[0061] Furthermore, the casting mold employing at least six blade forming cavities arranged in a straight line, which allows multiple blades to be obtained simultaneously in a single casting, combined with at least six clamping vibration systems on the equipment, enables the demolding of multiple blades to be processed in parallel. After the molten metal is cast, the six blade forming cavities are connected together above the riser. When the riser is clamped by a jig, the casting part connected above each blade riser can assist the jig in fixing each blade, thereby improving assembly efficiency. Moreover, when each vibrator 2 applies vibration to the blade riser, the vibration applied by each vibrator 2 to the blade riser can also be transmitted from the casting connection part above the blade riser, thereby assisting in the demolding of the blades.
[0062] The buffer structure 3 includes a layered rubber buffer layer and a polyurethane buffer layer. During the vibration demolding process, vibration will inevitably be transmitted to the drive components of the fixture. Especially after repeated vibrations, frequent vibrations will cause the drive components of the fixture to age or fail, thus seriously affecting the life of the equipment.
[0063] The buffer structure 3 uses a combination of rubber buffer layer and polyurethane buffer layer. The rubber buffer layer has a great elastic deformation capacity, which can efficiently absorb the impact generated by the vibrator 2 and reduce the peak impact force transmitted to the driving component of the fixture. The polyurethane buffer layer, with its wear resistance and elasticity, maintains dimensional stability during repeated compression and rebound, avoiding indentation or permanent deformation due to long-term impact.
[0064] Reference Figure 1 and Figure 3 The workbench 1 is equipped with U-shaped channel steel 7 with the slot opening facing upwards. The number of U-shaped channel steel 7 matches the number of clamping vibration systems. The workbench 1 and the U-shaped channel steel 7 have openings that pass through the workbench 1 and the U-shaped channel steel 7 vertically. The clamp is set inside the U-shaped channel steel 7, and the clamping jaw of the clamp is located above the opening.
[0065] The clamp is built into the U-shaped channel steel 7. The through opening between the workbench 1 and the U-shaped channel steel 7 provides a passage for the aircraft blades and risers. The clamp holds the risers, and the aircraft blades pass through the opening and hang below the workbench 1. This application utilizes the two side walls of the U-shaped channel steel 7 to intercept the splash residue generated during the vibration chip removal process inside the U-shaped channel steel 7, forcing the splash residue to fall only along the opening to below the workbench 1, thereby ensuring that the workstation can remain clean for a long time, thus reducing the need for frequent cleaning by operators and also reducing the labor of operators.
[0066] The fixture includes a stroke-adjustable cylinder 8, a positioning block 9, and two clamping blocks 10. The extension and retraction end of the cylinder 8 is provided with a buffer structure 3. One clamping block 10 is set on the buffer structure 3, and the other clamping block 10 is set on the positioning block 9. The clamping jaw is set between the two clamping blocks 10.
[0067] In this application, cylinder 8 is a three-rod cylinder. A stroke adjustment shaft is provided at the rear end of the cylinder body of the three-rod cylinder. The stroke adjustment shaft is linked with the piston rod inside the cylinder 8. By rotating the stroke adjustment shaft, the maximum extension length of the piston rod can be changed, thereby adjusting the extension length of the telescopic end of the cylinder 8.
[0068] The positioning block 9 is positioned opposite to the cylinder 8, and the positioning block 9 and the cylinder 8 are located on opposite sides of the clamping jaw. The two clamping blocks 10 are a moving clamping block and a fixed clamping block, respectively. The surfaces of the two clamping blocks 10 that contact the riser of the aircraft blade are pre-machined into shapes that match the riser profile of the aircraft blade to increase the contact area and reduce the contact stress.
[0069] The telescopic end of cylinder 8 is fixedly connected to one end of buffer structure 3, and the other end of buffer structure 3 is fixedly connected to moving clamp block. Another clamp block 10 is directly fixed to positioning block 9. Buffer structure 3 may not be provided between the fixed clamp block and positioning block 9, or an auxiliary buffer layer may be provided as needed. A clamping opening is formed between the two clamp blocks 10. When the telescopic end of cylinder 8 extends, the moving clamp block moves towards the fixed clamp block, reducing the distance between the two clamp blocks 10, thereby clamping the riser of the aircraft blade located between the moving and fixed clamp blocks. When the telescopic end of cylinder 8 retracts, the distance between the two clamp blocks 10 increases, thereby releasing the riser of the aircraft blade.
[0070] The operator can adjust the stroke parameters of the cylinder 8 to make the two clamping blocks 10 fit the sides of the riser with appropriate pressure. This will prevent the stress from being transmitted to the blade due to excessive clamping of the riser, and will also prevent relative slippage due to excessive looseness, thus maintaining a stable clamping force.
[0071] The control switch for cylinder 8 of the clamping vibration system is located on the worktable 1. By bringing together the switches of each independent unit, the operator can complete the clamping and releasing actions of all stations from one position, enabling centralized control during the batch demolding of aircraft blades, thereby improving the demolding efficiency of batch demolding operations.
[0072] The fixture is covered with a protective pad. When the vibrating end of the vibrator 2 vibrates and strikes the fixture due to external force deviating from the target, the protective pad can protect the fixture from direct impact and damage, avoiding damage to the fixture caused by accidental impact.
[0073] At least six vibrators 2 vibrate at staggered frequencies. That is, the six vibrators 2 installed on the same equipment have different vibration frequencies, or are adjusted to different operating frequencies. By staggering the vibration frequencies of at least six vibrators, resonance caused by multiple vibrators working simultaneously is effectively avoided, the concentrated superposition of vibration energy at a single frequency is eliminated, and impact damage to the fixture is prevented by resonance.
[0074] The vibrating ends of the vibrators 2 of two adjacent clamping vibration systems are arranged opposite each other, thus forming an alternating arrangement of the vibrators 2 and the buffer structure 3 in the arrangement direction of the clamping vibration system. This disperses the vibrators 2 on the worktable 1, increases the physical distance between adjacent vibration sources, weakens the vibration coupling between workstations, and prevents resonance from causing impact damage to the fixture.
[0075] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A casting and demolding process for aircraft blades, characterized in that, The casting mold is provided with blade forming cavities. The casting mold is made of one piece and has at least 6 blade forming cavities arranged in a straight line. Cast the blades, and after the blades cool, clean out the blade risers; The demolding process uses a composite demolding device: The composite demolding equipment includes a worktable (1), a clamping vibration system, an ultrasonic vibration system, and a drying system; The workbench (1) has a surface higher than the blade length; The workbench (1) is equipped with at least 6 clamping vibration systems; The clamping vibration system includes a clamp and a vibrator (2); The clamp has a jaw for holding the blade riser, with the top of the blade riser protruding outside the jaw; A buffer structure (3) is provided on one side of the clamp; The vibrator (2) is located on the other side of the clamp and is opposite to the buffer structure (3). The range of motion of the vibrating end of the vibrator (2) covers the area above the clamp. The ultrasonic vibration system includes a tubular container (4) suspended below the table to accommodate the blades, and an openable plug (5) is provided at the lower end of the tubular container (4). The ultrasonic generator of the ultrasonic vibration system is located on the plug (5). After the plug (5) is closed, the ultrasonic generator is encapsulated in the tubular container (4). The drying system has hot air inlets; The tubular container (4) has at least four air vents (6) arranged in a ring at the top, and the hot air vent is connected to the at least four air vents (6); The demolding process steps are as follows: a: Use a clamp to hold the blade riser and tap the casting mold to expose the blade; b: Assemble the tubular container (4), with the blades extending into the tubular container (4); c: Open the plug (5) and start the vibrator (2) to apply vibration to the riser; d: Turn off the vibrator (2) and the plug (5), fill the tubular container (4) with water until the blades are submerged, and start the ultrasonic generator to vibrate; e: Turn off the ultrasonic generator, open the plug (5), and introduce hot air into the air vent (6); f: Open the plug (5), apply vibration to the riser again, and repeat steps c~f after the vibration ends; g: After the blades are demolded, cut off the portion of the blade riser that is exposed above the clamp.
2. The aircraft blade casting and demolding process according to claim 1, characterized in that, The buffer structure (3) includes a rubber buffer layer and a polyurethane buffer layer stacked together.
3. The aircraft blade casting and demolding process according to claim 1, characterized in that, The workbench (1) is provided with U-shaped channel steel (7) with the slot opening facing upwards, and the number of U-shaped channel steel (7) matches the number of clamping vibration systems; The workbench (1) and the U-shaped channel steel (7) have an opening that runs vertically through the workbench (1) and the U-shaped channel steel (7); The clamp is disposed inside the U-shaped channel steel (7), and the clamping jaw of the clamp is located above the opening.
4. The aircraft blade casting and demolding process according to claim 1, characterized in that, The clamp includes a stroke-adjustable cylinder (8), a positioning block (9), and two clamping blocks (10); The buffer structure (3) is provided at the telescopic end of the cylinder (8); One clamping block (10) is disposed on the buffer structure (3), and the other clamping block (10) is disposed on the positioning block (9); The clamp is located between the two clamping blocks (10).
5. The aircraft blade casting and demolding process according to claim 4, characterized in that, The control switch for the cylinder (8) of the clamping vibration system is located on the workbench (1).
6. The aircraft blade casting and demolding process according to claim 1, characterized in that, The clamp is covered with a protective pad.
7. The aircraft blade casting and demolding process according to claim 1, characterized in that, At least 6 vibrators (2) vibrate at staggered frequencies.
8. The aircraft blade casting and demolding process according to claim 1, characterized in that, The vibrating ends of the vibrators (2) of two adjacent clamping vibration systems are arranged opposite each other.
9. The aircraft blade casting and demolding process according to claim 1, characterized in that, After the blade extends into the tubular container (4), there is a gap between the blade and the inner wall of the tubular container (4), with a gap distance of 3~8mm.