A method and apparatus for the assembly of complex leaf-shape guide casting wax mold

Abstract

The present application relates to the technical field of precision casting, in particular to a method and equipment for combined forming of a wax mold of a complex vane guide casting. The method for combined forming of a wax mold of a complex vane guide casting provided by the present application comprises the following steps: taking the intersection between the blade tip of the vane guide and the inner wall of the sleeve as a split surface, splitting the vane guide wax mold into an inner ring wax part and a sleeve wax part, the inner ring wax part having the vane of the vane guide, and separately forming the inner ring wax part and the sleeve wax part by wax injection; positioning and combining the inner ring wax part and the sleeve wax part, and bonding and fixing the inner ring wax part and the sleeve wax part to obtain a combined wax part, the tip of each vane in the combined wax part and the inner wall of the sleeve wax part forming a splicing part respectively; dripping photosensitive resin to the splicing part, and performing photocuring on the photosensitive resin after dripping. The present application simplifies the mold structure, reduces the risk of wax part defects, realizes the automatic forming of the vane tip fillet, and improves the size consistency and batch stability of the wax mold.

Description

Technical Field

[0001] This invention relates to the field of precision casting technology, and in particular to a method and apparatus for assembling wax molds for castings of complex leaf-shaped guides. Background Technology

[0002] The guide vane is a core hot-end component in gas turbines and aero engines, used to rectify and guide airflow. A guide vane typically consists of several blades evenly distributed circumferentially, with each blade connected to an inner ring and an outer ring at its two ends, forming a ring-shaped assembly. The blade profile is a twisted curved surface, and flow channels are formed between adjacent blades; when there are many blades, these flow channels are densely arranged circumferentially.

[0003] Guide castings are typically made using investment casting, with the wax pattern serving as the core carrier. Its dimensional accuracy and surface quality directly determine the final casting quality. Currently, the conventional method for preparing guide wax patterns is integral wax injection: wax is injected into a single mold, simultaneously forming all surfaces of the blades, inner ring, and outer ring.

[0004] However, the blade profile is a spatially twisted curved surface, with each blade arranged circumferentially, forming closed or semi-closed flow channel spaces between the blades. When the blade installation angle is large and the flow channel is narrow, each flow channel in the wax model cavity cannot be directly demolded in a single direction, and movable blocks must be set at each flow channel position. The number of movable blocks is the same as the number of blades. For guides with a large number of blades, a considerable number of movable blocks need to be set in the mold, which makes the mold structure more complex and increases the difficulty of processing and assembly. Before each wax pressing, all movable blocks need to be installed into the mold cavity one by one, and after wax pressing, they need to be removed one by one. The assembly and disassembly operations are time-consuming, and the installation sequence and positioning accuracy of the movable blocks affect the size of the wax part. There are mating gaps between movable blocks and between movable blocks and the mold body. When waxing, the wax material is squeezed out of the gaps to form flash, leaving step marks on the surface of the wax part, which need to be manually repaired one by one before proceeding to the next process. After repeated assembly and disassembly, the mating surfaces of the movable blocks wear, the gaps gradually increase, and the dimensional repeatability of the wax part decreases with the number of uses. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a method and apparatus for assembling and molding wax models of complex blade-shaped guide castings. The method provided by this invention simplifies the mold structure and reduces the risk of wax defects by splitting the guide wax model into inner ring wax parts and outer ring wax parts for separate wax injection molding. Furthermore, it replaces manual wax trimming by using photosensitive resin to drip and cure at the splicing parts, thereby achieving automated forming of the blade tip rounded corners and improving the dimensional consistency and batch stability of the wax model.

[0006] (II) Technical Solution To achieve the above objectives, this application provides a method for assembling and molding a wax model of a complex blade-shaped guide casting, comprising the following steps: using the junction of the blade tip and the inner wall of the outer sleeve as the splitting surface, the guide wax model is split into an inner ring wax part and an outer sleeve wax part, the inner ring wax part having the blade of the guide; the inner ring wax part and the outer sleeve wax part are respectively injection molded; the inner ring wax part and the outer sleeve wax part are positioned and assembled, and the inner ring wax part and the outer sleeve wax part are bonded and fixed to obtain an assembled wax part, wherein the blade tip of each blade in the assembled wax part and the inner wall of the outer sleeve wax part respectively form splicing parts; photosensitive resin is dripped into the splicing parts, and the dripped photosensitive resin is photocured to form rounded corners at the splicing parts.

[0007] In one possible implementation, the inner ring wax part is removed by unscrewing after wax injection molding, while the outer ring wax part is removed by opening the mold from top to bottom after wax injection molding.

[0008] In one possible implementation, when dripping photosensitive resin onto the splicing area, the combined wax component is clamped on a turntable, and the tilt angle of the turntable is adjusted so that the dripping head located above the turntable does not interfere with the combined wax component, and the dripped photosensitive resin can flow along the splicing area; the position of the dripping head is adjusted so that the dripping head is directly opposite the tip of the blade at the air inlet edge.

[0009] In one possible implementation, the number of rotations of the turntable is set according to the number of blades in the guide, and the volume of photosensitive resin dispensed in a single drip is set according to the length of the splicing part.

[0010] In one possible implementation, after the drip head completes the dripping of the splice corresponding to the current blade, the splice corresponding to the current blade is irradiated with an ultraviolet lamp to preliminarily cure the photosensitive resin therein; then the turntable rotates so that the drip head is facing the splice corresponding to the next blade and dripping is performed.

[0011] In one possible implementation, after the splicing parts corresponding to each blade have been dripped and pre-cured, the assembled wax parts are placed in an ultraviolet curing chamber for irradiation, so that the photosensitive resin at each splicing part is fully cured.

[0012] In one possible implementation, the photosensitive resin is a wax-containing photosensitive resin.

[0013] Secondly, the present invention also provides an apparatus for assembling and molding wax models of complex leaf-shaped guide castings, and a method for assembling and molding wax models of guide castings as described above, comprising: a base; a turntable assembly disposed on the base, including a turntable and a servo motor for driving the turntable to rotate, the turntable being provided with a wax model fixing fixture for clamping the assembled wax model, the tilt angle of the turntable being adjustable; a dripping assembly including a dripping tube and a dripping head disposed at the lower end of the dripping tube, the dripping tube being used to store photosensitive resin, the dripping head being located above the turntable so that the photosensitive resin can drip out through the dripping head under air pressure; a curing assembly including an ultraviolet lamp for irradiating the splicing parts; and a control host for controlling the rotation of the turntable, the dripping action of the dripping assembly, and the on / off state of the ultraviolet lamp.

[0014] In one possible implementation, the system also includes a main support arm, a connecting seat, and a side arm. The main support arm is fixed to the base, and the connecting seat is movably mounted on the main support arm. The main support arm is equipped with a height adjustment component that drives the connecting seat to move up and down. One end of the side arm is connected to the connecting seat, and the other end is equipped with a fixed seat, on which the drip tube is mounted.

[0015] In one possible implementation, the turntable assembly also includes a motor mount disposed on a base, on which a servo motor is rotatably mounted to adjust the tilt angle of the turntable; the motor mount is provided with an angle fixing knob for locking the tilt angle of the turntable, and an angle indicator for indicating the tilt angle of the turntable.

[0016] In one possible implementation, the drip assembly further includes a top cover and an air tube, with the top cover sealing the upper end of the drip tube; the control unit contains a control circuit, a solenoid valve, a pressure sensor, and an air pump, with one end of the air tube connected to the top cover and the other end connected to the air pump, the air pump supplying air to the drip tube through the air tube, and the control circuit adjusting the air pressure in the drip tube through the solenoid valve based on the detection signal from the pressure sensor, so as to control the drip volume and drip speed of the photosensitive resin.

[0017] In one possible implementation, the curing assembly includes an upper UV lamp and a lower UV lamp, with the upper UV lamp positioned on one side of the dispensing head and the lower UV lamp positioned on a turntable.

[0018] In one possible implementation, the control host also includes a display screen, and the control circuit can be connected to a host computer to set parameters for different products, including the number of blades, drip volume, drip rate, drip interval, and irradiation time.

[0019] In one possible implementation, the dropper is used to store the wax-containing photosensitive resin.

[0020] (III) Beneficial Effects Compared with the prior art, the present invention provides a method and apparatus for assembling and molding wax molds for castings of complex leaf-shaped guides, which has the following beneficial effects: The method for assembling and molding wax models of complex blade-shaped guide castings provided by this invention splits the guide wax model into an inner ring wax model and an outer ring wax model, with the junction of the blade tip and the inner wall of the outer sleeve as the boundary. The blades of the inner ring wax model open outward at the blade tip, and the flow channels are no longer blocked by the outer sleeve on the radial outer side, changing from a closed state to an open state. The cavity structure of the inner ring mold is greatly simplified, and the number of movable blocks is significantly reduced or even eliminated. This avoids the problems of cumbersome assembly and disassembly of movable blocks, flash caused by the fit gap, and reduced dimensional repeatability of wax parts due to wear of the fit surface in the overall wax pressing method. The outer ring wax model is an annular shell without blades, with a simple cavity structure. There is no special difficulty in wax injection and demolding. The structural complexity of each mold is lower than that of the overall mold. After the two wax parts are positioned and bonded together, a joint is formed between the blade tip and the inner wall of the outer casing. Photosensitive resin is dripped into this joint, and under the influence of gravity and capillary force, the resin flows into the gap and forms a meniscus at the gas-liquid interface due to surface tension, naturally creating a smooth, rounded corner profile. Subsequently, it is cured by light, and the rounded corner shape is stably locked. The entire rounded corner forming process does not involve manual contact or tool operation. The consistency of the rounded corner shape at each joint is determined by the material flow characteristics and surface tension, ensuring stable repeatability between batches. This solves the problem of poor batch consistency caused by manual wax repair in the overall waxing method, where the rounded corner shape is affected by the operator's skill level. It also eliminates the risk of cracking and detachment caused by the inconsistent thermal expansion behavior of the repair wax and the main wax material. Attached Figure Description

[0021] Figure 1 A flowchart illustrating a method for assembling and molding wax models of complex leaf-shaped guide castings provided by the present invention; Figure 2 This invention provides a three-dimensional structural diagram of a guide wax mold during bonding and positioning. Figure 3 A top view of a guide wax mold provided by the present invention; Figure 4 for Figure 3 A schematic diagram of the cross-sectional structure of the guide wax model along the AA direction. Figure 5 This is a three-dimensional structural schematic diagram of a device for assembling and molding wax molds of complex leaf-shaped guide castings provided by the present invention; Figure 6 This is a top view schematic diagram of a device for assembling and molding wax molds of complex leaf-shaped guide castings provided by the present invention; Figure 7 yes Figure 6 A schematic diagram of the cross-sectional structure along the BB direction.

[0022] Marked in the attached diagram: a. Guide wax model; a1. Inner ring wax part; a2. Outer ring wax part; a3. Blade; a4. Jointing part; 1. Base; 2. Turntable assembly; 21. Turntable; 22. Servo motor; 23. Fixture; 24. Motor mount; 25. Angle fixing knob; 26. Angle indicator dial; 3. Drip assembly; 31. Drip tube; 32. Drip head; 33. Main support arm; 34. Connecting seat; 35. Side arm; 36. Height adjustment component; 37. Fixing seat; 4. Curing components; 41. Ultraviolet lamp; 5. Control host. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figures 1 to 7 This application provides a method for assembling and molding wax models of complex leaf-shaped guide castings, comprising the following steps: S1. Using the junction of the blade tip of the guide a3 and the inner wall of the outer sleeve as the splitting surface, the guide wax model a is split into an inner ring wax part a1 and an outer wax part a2. The inner ring wax part a1 has the blade a3 of the guide. The inner ring wax part a1 and the outer wax part a2 are respectively injection molded. S2. Position and combine the inner ring wax piece a1 and the outer ring wax piece a2, and then bond and fix the inner ring wax piece a1 and the outer ring wax piece a2 to obtain the combined wax piece. The blade tip of each blade a3 in the combined wax piece and the inner wall of the outer ring wax piece a2 respectively form splicing parts a4. S3. Apply photosensitive resin to the splicing part a4, and then perform photocuring on the applied photosensitive resin to form a rounded corner at the splicing part a4.

[0025] In this invention, the preparation of the guide wax mold a is divided into two parts: an inner ring wax part a1 and an outer ring wax part a2, which are molded separately. After assembly, photosensitive resin is dripped into the splicing part a4 between the blade tip and the inner wall of the outer ring. After curing under light, a rounded corner is formed at the splicing part a4. The blade a3 profile and the outer ring rotating surface are processed separately, which reduces the complexity of the corresponding molding mold cavity. The rounded corner of the splicing part a4 is formed by the liquid resin flowing at the angle to form a meniscus and then curing. The outline shape of the rounded corner is naturally determined by the surface tension and flow characteristics of the resin, without relying on manual trimming.

[0026] Specifically, the inner ring wax part a1 carries the blade a3 profile of the guide, and the outer wax part a2 corresponds to the outer shell structure of the guide. Both are assembled by injection molding using their respective molds. The splicing part a4 refers to the strip-shaped angle area formed by the intersection of the blade tip and the inner wall of the outer shell. After the photosensitive resin is dripped into this angle in liquid form, it forms a concave arc contour within the angle. After being irradiated with ultraviolet light, it cross-links and cures. The cured resin rounded corner adheres to the surface of the wax part, becoming part of the combined wax model surface. During subsequent shell making, the shell mold replicates the corresponding concave rounded corner shape at this location, and the casting obtains the required transition rounded corner.

[0027] In one specific embodiment, the blade a3 of a certain type of turbine guide vane has a large installation angle and a narrow flow channel width between adjacent blades a3. A transition radius is required at the root of the blade tip to reduce stress concentration. After split molding, a sharp-angle gap is formed at the joint between the blade tip and the inner wall of the outer casing. After dripping photosensitive resin at this point, the resin spreads along the included angle to form a continuous arc surface. After curing, the joint is sealed and the corner is filled. After shell making, dewaxing, and casting, the transition area at the root of the blade tip of the casting is intact, and no casting cracks caused by the sharp corner appear.

[0028] In related technologies, the guide wax model a is usually prepared by integral wax pressing. The mold needs to set a movable block at the flow channel position of each blade a3. When there are many blades a3, the number of movable blocks increases accordingly. Each wax pressing requires manual insertion and removal of movable blocks one by one, which is time-consuming. The fit gap between movable blocks and between movable blocks and the mold body will leave flash and step marks on the surface of the wax part, which need to be repaired one by one. After a period of use, the movable blocks wear down, and the dimensional repeatability of the wax part decreases accordingly.

[0029] In this embodiment of the invention, the inner ring wax part a1 and the outer wax part a2 are formed separately. Their respective forming molds do not need to be equipped with flow channels or movable blocks, which simplifies the mold structure. No traces left by the gaps between the movable blocks are produced on the surface of the wax parts, and the amount of wax repair work is reduced accordingly. The rounded corners of the splicing part a4 are generated by dripping and curing photosensitive resin. The curing speed is fast, and the shape is stable after curing. It is not affected by temperature fluctuations in subsequent processes and will not soften or deform. Compared with the manual repair method of piling up repair wax, the operation is less dependent on personal skills.

[0030] In some embodiments, the inner ring wax part a1 is removed by unscrewing after wax injection molding, and the outer ring wax part a2 is removed by opening the mold from the top and bottom after wax injection molding.

[0031] In this invention, the splitting surface between the inner ring wax piece a1 and the outer ring wax piece a2 is located at the junction of the blade tip and the inner wall of the outer ring. The blade a3 is retained entirely on the inner ring wax piece a1, and the inner ring wax piece a1 is ejected from the molding die by rotation. By placing the splitting surface at the blade tip, all blades a3 are located on one side of the inner ring wax piece a1. The blades a3 have circumferentially arranged surfaces with consistent twisting direction, providing the geometric conditions for rotational demolding. Therefore, the mold for molding the inner ring wax piece a1 does not need to provide movable blocks for each blade a3. The outer ring wax piece a2 has a rotating structure and is directly demolded axially.

[0032] Specifically, the guide blades a3 are typically evenly distributed circumferentially, with each blade a3 having a consistent direction of twist. The outer contour of the inner ring wax piece a1 is formed by the surfaces of the blades a3. The consistent twist of each blade a3 allows the inner ring wax piece a1 to rotate around the axis relative to the mold cavity and exit—the rotation angle matches the amount of twist of the blades a3. During rotation, the blades a3 detach from the sidewalls of the cavity along their respective helical trajectories, and all blades a3 are demolded simultaneously. The inner and outer surfaces of the outer wax piece a2 are both surfaces of revolution, and demolding can be achieved simply by opening and closing along the axial direction, without the need for additional movable blocks.

[0033] In one specific embodiment, a guide vane a3 has a large bending angle. If integral wax pressing is used, each flow channel needs to be equipped with a movable block, resulting in a long wax pressing cycle. According to the present invention, after setting the splitting surface at the vane tip, the inner ring wax part a1 mold is designed with a rotational demolding stroke according to the twisting direction of the vane a3. After molding, the part is rotated and removed, and the surface of the vane a3 is undamaged. The outer wax part a2 mold opens and closes axially for direct demolding. Neither mold needs to be equipped with movable blocks, thus shortening the wax pressing cycle.

[0034] In this embodiment of the invention, the splitting surface is located at the junction of the blade tip and the inner wall of the outer casing. The blade a3 is completely retained on the inner ring wax a1 side, and the outer casing wax a2 is a pure rotating body. Neither mold needs to set a movable block. This splitting position is a direct way to avoid setting movable blocks for both molds at the same time. The rotation demolding method of the inner ring wax a1 does not force interference on the surface of the blade a3, and the integrity of the surface is guaranteed after the wax is removed.

[0035] In some embodiments, when dripping photosensitive resin onto the splicing part a4, the combined wax component is clamped on the turntable 21, and the tilt angle of the turntable 21 is adjusted so that the dripping head 32 located above the turntable 21 does not interfere with the combined wax component, and the dripped photosensitive resin can flow along the splicing part a4; the position of the dripping head 32 is adjusted so that the dripping head 32 is directly opposite the tip of the air intake edge of the blade a3.

[0036] In this invention, the turntable 21 with the combined wax parts is adjusted to an inclined state so that the splicing part a4 is exposed from the outer sleeve opening. The photosensitive resin is dripped from the air intake side of the blade a3 on the highest position side. Under the action of gravity, the resin flows along the groove formed by the blade tip and the inner wall of the outer sleeve towards the exhaust side, spreading and covering the entire splicing part a4.

[0037] Specifically, the splice section a4 is located within the angle between the blade tip and the inner wall of the outer casing, and the outer casing wall blocks the dripping operation performed from directly above. After the turntable 21 is tilted, the outer casing axis deviates from the vertical direction, and the angled area between the blade tip and the inner wall of the outer casing on the upper side is exposed from the outer casing port, allowing the dripping head 32 to directly face this area from an obliquely upward position. The dripping starts from the inlet edge, utilizing the characteristic that the resin flows directionally along the angled groove under the influence of gravity in the tilted state—the inlet edge is at a higher position, and after the resin drips down, it flows along the angled groove towards the lower exhaust edge, filling the splice along the way. A single drip can cover the entire splice section a4 without requiring the dripping head 32 to move relative to the splice.

[0038] In this embodiment of the invention, the splicing part a4 is exposed by tilting the turntable 21, and the resin is guided by gravity to flow and spread along the included groove. The entire seam can be covered by only one fixed drip point, without the need for the drip head 32 to move along the seam direction. The movement mechanism of the equipment can be simplified, and the drip head 32 maintains a distance from the blade a3 profile, reducing the risk of damaging the wax profile during operation.

[0039] In some embodiments, the number of rotations of the turntable 21 is set according to the number of blades a3 of the guide, and the volume of photosensitive resin dispensed in a single drip is set according to the length of the splicing part a4.

[0040] In this invention, the number of indexing rotations of the turntable 21 and the indexing angle of each rotation are set according to the number of guide blades a3. A quantitative drip is applied to each splicing part a4 according to the set volume, and all splicing parts a4 are traversed.

[0041] Specifically, the guide blades a3 are evenly distributed circumferentially, and the included angle between adjacent blades a3 is the division angle. Each time the turntable 21 rotates through one division angle, it sends the next splicing part a4 to the dripping position. The number of cycles is equal to the number of blades a3, thus completing the dripping of all splicing parts a4. The resin dripping amount for each splicing part a4 is given by a set volume, which is determined according to the length of the joint, the cross-sectional shape, and the required fillet size. Each time dripping is triggered, this set amount is executed.

[0042] In one specific embodiment, the guide vanes a3 are evenly distributed circumferentially. After full circumferential indexing is completed according to the indexing angle corresponding to the number of vanes a3, the splicing parts a4 of each vane a3 have all been dripped without omission. Since the dripping amount of each part is the same set value, the cross-sectional dimensions of the fillet of each part are consistent after curing. The fillet shape of different vane a3 positions on the same part is consistent, and there is no difference in fillet size caused by the different amounts of dripping each time when the operator manually drips at each station.

[0043] In some embodiments, after the drip head 32 completes the dripping of the splicing part a4 corresponding to the current blade a3, the ultraviolet lamp 41 irradiates the splicing part a4 corresponding to the current blade a3 to preliminarily cure the photosensitive resin therein; then the turntable 21 rotates so that the drip head 32 is facing the splicing part a4 corresponding to the next blade a3 and dripping is performed.

[0044] In this invention, after each splicing part a4 is dripped, the splicing part a4 is irradiated with ultraviolet light to pre-cur the photosensitive resin, and then the turntable 21 is driven to rotate to the next splicing part a4 for dripping, and so on in a station-by-station cycle.

[0045] Specifically, pre-curing involves subjecting the freshly poured resin to short-term ultraviolet irradiation, causing cross-linking of the resin surface, a significant increase in viscosity, and loss of fluidity, thus locking in the meniscus shape that has already been spread. After pre-curing, the turntable 21 rotates to the next station. At this point, the resin at the previous station no longer possesses fluidity, and the changes in the wax part's posture caused by the rotation of the turntable 21 no longer alter the shape of the cured resin. The pre-curing irradiation time is short and can be scheduled within the interval before the indexing action, seamlessly connecting with the pouring cycle.

[0046] In this embodiment of the invention, a step-by-step cyclic method of pre-curing immediately after dripping and then indexing is adopted. Each resin is fixed when it is in the best shape, and the rounded corner shape of each splicing part a4 is not affected by the subsequent indexing action. Compared with the method of uniform curing after all dripping is completed, the uniformity of the rounded corner shape of each part is guaranteed by the process sequence, rather than relying on the resin to remain still during the waiting period.

[0047] In some embodiments, after the splicing parts a4 corresponding to each blade a3 have been dripped and initially cured, the combined wax parts are placed in an ultraviolet curing chamber for irradiation, so that the photosensitive resin of each splicing part a4 is completely cured.

[0048] In this invention, after all splicing parts a4 are dripped and pre-cured, the entire composite wax mold is irradiated with ultraviolet light to fully cure the photosensitive resin of each splicing part a4.

[0049] Specifically, the purpose of pre-curing is to quickly lock in the resin morphology. The irradiation time is short, and the degree of cross-linking within the resin is limited; at this stage, the strength of the resin layer is lower than that of the fully cured state. Final curing involves irradiating the entire assembled wax mold for a sufficient amount of time to ensure complete cross-linking of the resin throughout, achieving the required strength and adhesion to the wax surface for subsequent shell-making processes. Final curing can be performed on this equipment or by moving the assembled wax mold to a separate UV curing chamber; the latter does not occupy time on this equipment.

[0050] In this embodiment of the invention, curing is divided into two stages: pre-curing and final curing. The pre-curing time is short, with the cumulative pre-curing time at each station being much less than the total time for direct and complete curing at each station. The final curing involves a single irradiation of the entire system, and its time does not increase proportionally with the number of blades (a3). The two stages are clearly defined, ensuring that both the process cycle time and the final curing quality requirements are met simultaneously. Compared to using pre-curing or final curing alone, the combination of the two achieves a balance between cycle time and quality.

[0051] In some embodiments, the photosensitive resin is a wax-containing photosensitive resin.

[0052] In this invention, the introduction of the wax component improves the wetting affinity between the resin and the surface of the wax part. After dripping, the resin spreads more fully on the surface of the wax part, and the interface bonding between the resin and the surface of the wax part is more reliable after curing, making it less likely to detach during handling and shell making operations.

[0053] In this embodiment of the invention, the thermal behavior of the cured product of the wax-containing photosensitive resin at the dewaxing temperature is close to that of the mold material. The dewaxing process does not require special adjustments for the rounded corner resin, thus reducing the impact on the original dewaxing process parameters. Compared with ordinary photosensitive resin, it reduces the risk of casting inclusions introduced by the cured residue, and there is no need to add a treatment step for resin residue in addition to the existing dewaxing process.

[0054] like Figures 5 to 7 As shown, the present invention also provides a device for assembling and molding wax molds of complex leaf-shaped guide castings, comprising: a base 1; a turntable assembly 2, disposed on the base 1, including a turntable 21 and a servo motor 22 for driving the turntable 21 to rotate, the turntable 21 being provided with a wax fixing fixture 23 for clamping the assembled wax parts, the tilt angle of the turntable 21 being adjustable; a dripping assembly 3, including a dripping tube 31 and a dripping head 32 disposed at the lower end of the dripping tube 31, the dripping tube 31 being used to store photosensitive resin, the dripping head 32 being located above the turntable 21 so that the photosensitive resin can drip out through the dripping head 32 under air pressure; a curing assembly 4, including an ultraviolet lamp 41 for irradiating the splicing part a4; and a control host 5, for controlling the rotation of the turntable 21, the dripping action of the dripping assembly 3, and the opening and closing of the ultraviolet lamp 41.

[0055] In this invention, the device for drip-curing the guide assembly wax mold includes a turntable 21, a support assembly, a drip tube 31 assembly, an ultraviolet lamp 41, and a control host 5. The turntable 21 is used to install and index the assembled wax parts. The support assembly carries the drip tube 31 assembly. The drip tube 31 assembly completes the quantitative dripping of resin. The ultraviolet lamp 41 completes the curing irradiation. The control host 5 coordinates the action sequence of each component, so that the dripping, pre-curing, and indexing actions are automatically and cyclically executed.

[0056] Specifically, the turntable 21 is equipped with a fixture that mates with the combined wax pieces. After the combined wax pieces are installed, their rotation center is aligned with the axis of the turntable 21. The turntable 21 is driven by a drive mechanism to rotate at set angles, and each rotation delivers the next splicing part a4 to the dispensing position. The dispensing tube 31 assembly stores photosensitive resin, and under the trigger of a control signal, a set volume of resin is dispensed through the dispensing head 32. The ultraviolet lamp 41 is installed at a position that can irradiate the splicing part a4, and emits ultraviolet light under the trigger of a control signal. The control host 5 has built-in control logic, which sequentially triggers the dispensing, ultraviolet lamp 41 irradiation, and turntable 21 rotation according to the program, and executes the cycle until all splicing parts a4 are processed.

[0057] In this embodiment of the invention, the equipment integrates four functions: clamping, indexing, dripping, and curing. It is uniformly scheduled by the control host 5. The dripping volume and curing time of each station are determined by program parameters. The consistency of the operation results is independent of the operator's current state. The actions of each station are automatically connected. The working time of a single piece is determined by the program cycle time and does not change with the operator's skill level. The personnel occupation is reduced to wax loading and unloading operations.

[0058] In some embodiments, the device further includes a main support arm 33, a connecting seat 34, and a side arm 35. The main support arm 33 is fixed to the base 1, and the connecting seat 34 is movably mounted on the main support arm 33. The main support arm 33 is provided with a height adjustment component that drives the connecting seat 34 to move up and down. One end of the side arm 35 is connected to the connecting seat 34, and the other end is provided with a fixed seat 37. The drip tube 31 is mounted on the fixed seat 37.

[0059] In this invention, the support assembly includes a main support arm 33, a connecting seat 34, a height adjustment component, and a side arm 35. The main support arm 33 is fixed to the base 1. The connecting seat 34 moves up and down along the main support arm 33 and is driven by the height adjustment component. The side arm 35 extends horizontally from the connecting seat 34 to above the turntable 21 and has a fixed seat 37 at its end. The drip tube 31 is detachably installed on the fixed seat 37.

[0060] Specifically, the main support arm 33 serves as the fixed reference for the support assembly and is vertically mounted on the base 1. The connecting seat 34 moves up and down along the guide direction of the main support arm 33. The height adjustment component drives the connecting seat 34 to rise and fall and locks it at the target height, thereby adjusting the height of the drip head 32. The side arm 35 extends horizontally from the connecting seat 34 towards the turntable 21, and its extension length determines the radial position of the drip head 32 relative to the center of the turntable 21. The fixing seat 37 is located at the end of the side arm 35. After the drip tube 31 is inserted into or snapped into the fixing seat 37, it remains in the working position and can be removed from the fixing seat 37 during disassembly without disassembling other components.

[0061] In one specific embodiment, the outer sleeve height and diameter of different models of guides vary. When changing products, the drip head 32 needs to be adjusted to the height and radial position corresponding to the splicing part a4 of the new product. By adjusting the height of the connecting seat 34 on the main upright arm 33, products with different outer sleeve heights can be adapted; by selecting side arms 35 with different overhang lengths or setting an adjustment structure on the side arms 35, products with different outer sleeve diameters can be adapted; after both adjustments are completed and locked, it can be put into use.

[0062] In this embodiment of the invention, the height of the connecting seat 34 can be adjusted by the height adjustment component, so that the support component can be adapted to products with different outer sleeve heights within a certain range. When changing products, the height adjustment component can be adjusted to reposition the product without replacing the main body of the support component. The drip tube 31 is installed in a detachable manner on the fixed seat 37. When the resin is used up or the resin type needs to be changed, the drip tube 31 can be directly removed and replaced without affecting other parts of the support component. The cleaning operation can be carried out offline separately.

[0063] In some embodiments, the turntable assembly 2 further includes a motor mount 24 disposed on the base 1, and a servo motor 22 is rotatably mounted on the motor mount 24 to adjust the tilt angle of the turntable 21; the motor mount 24 is provided with an angle fixing knob 25 for locking the tilt angle of the turntable 21, and an angle indicator 26 for indicating the tilt angle of the turntable 21.

[0064] In this invention, the turntable 21 is mounted on the base 1 in a rotatable manner. The tilt angle of the turntable 21 is adjustable. The base 1 is provided with an angle indicator 26 to display the current tilt angle of the turntable 21. The base 1 is also provided with an angle fixing knob 25 to lock the turntable 21 at the adjusted tilt angle position.

[0065] Specifically, the ability to rotate turntable 21 means that turntable 21 can rotate relative to base 1 around a horizontal axis, changing the angle between the plane of turntable 21 and the horizontal plane, i.e., the tilt angle of turntable 21. The tilt angle affects the exposure degree of the splicing part a4 on the assembled wax piece, as well as the magnitude of the gravitational component experienced when the resin flows along the angled groove after dripping. It needs to be determined during debugging based on the installation angle of the blade a3 and the splice direction of the product. The angle indicator dial 26 provides a reading of the current tilt angle. After adjusting to the target tilt angle, the relative angle between turntable 21 and base 1 is locked by the angle fixing knob 25, so that the tilt angle of turntable 21 remains unchanged during subsequent indexing rotations.

[0066] In one specific embodiment, when changing products, the blade a3 installation angle of the new product is different from that of the previous product, and the required tilt angle of the turntable 21 is also different. The operator adjusts the turntable 21 to the target tilt angle according to the tilt angle value recorded in the process parameters and the angle indicator 26, and then tightens the angle fixing knob 25 before starting production. After production is completed, the tilt angle value corresponding to the product is recorded in the process parameter card. The next time production is carried out, the tilt angle can be directly readjusted according to the recorded value without the need to retest and confirm the tilt angle.

[0067] In this embodiment of the invention, the turntable 21 has an adjustable tilt angle and an angle indicator 26, and the current tilt angle value can be accurately read and recorded in the process file; the angle fixing knob 25 ensures that the tilt angle does not shift during the indexing rotation, and the stability of the tilt angle is maintained during the production process; when changing production, the tilt angle is readjusted according to the recorded value in the process file, and the adjustment result can be repeated, reducing the changeover and debugging time caused by tilt angle adjustment.

[0068] In some embodiments, the drip assembly 3 further includes a top cover and an air tube, with the top cover sealing the upper end of the drip tube 31; the control host 5 is equipped with a control circuit, a solenoid valve, a pressure sensor and an air pump, one end of the air tube is connected to the top cover and the other end is connected to the air pump, the air pump supplies air to the drip tube 31 through the air tube, and the control circuit adjusts the air pressure in the drip tube 31 through the solenoid valve according to the detection signal of the pressure sensor, so as to control the drip volume and drip speed of the photosensitive resin.

[0069] In this invention, the drip tube 31 assembly includes a top cover, a drip tube 31, and a drip head 32. The top cover seals the upper end of the drip tube 31. An air tube passes through the top cover and communicates with the inner cavity of the drip tube 31. The control host 5 introduces air pressure into the inner cavity of the drip tube 31 through the air tube, causing the photosensitive resin to drip out through the drip head 32. An air pressure sensor is provided inside the drip tube 31. The control host 5 adjusts the air pressure through a solenoid valve according to the signal from the air pressure sensor.

[0070] Specifically, the top cover seals the upper end of the drip tube 31, forming a closed air chamber. An air pump inside the control unit 5 introduces air pressure into this closed air chamber through an air pipe. This air pressure acts on the resin surface, pushing the resin downwards through the drip head 32. The air pressure determines the resin flow rate, and the ventilation time determines the flow rate; both together control the volume of resin dispensed per drip. A pressure sensor monitors the actual pressure inside the closed air chamber in real time. Based on the detection signal, the control unit 5 adjusts the air intake via a solenoid valve to maintain the air pressure at the set value, ensuring consistent driving conditions for each drip.

[0071] In one specific embodiment, the viscosity of the photosensitive resin fluctuates between different batches or due to changes in ambient temperature. This viscosity variation affects the actual dripping volume under the same air pressure and ventilation time. A pressure sensor and a solenoid valve form a pressure feedback regulation loop. When the actual air pressure deviates from the set value, the control unit 5 corrects this by adding or releasing air through the solenoid valve, stabilizing the driving pressure. This reduces the impact of resin viscosity fluctuations on the consistency of dripping volumes to some extent. Furthermore, significant viscosity changes can be compensated for by adjusting the air pressure set value.

[0072] In some embodiments, the curing component 4 includes an upper UV lamp 41 and a lower UV lamp 41, with the upper UV lamp 41 disposed on one side of the dispensing head 32 and the lower UV lamp 41 disposed on the turntable 21.

[0073] In this invention, the ultraviolet lamp 41 includes an upper ultraviolet lamp 41 and a lower ultraviolet lamp 41. The upper ultraviolet lamp 41 is mounted on the support assembly and located on one side of the drip head 32, irradiating the splicing part a4 from above; the lower ultraviolet lamp 41 is mounted on the turntable 21, irradiating the splicing part a4 from below.

[0074] Specifically, the upper UV lamp 41 is installed on the same side as the dispensing head 32. After dispensing is completed at the current station, it shines downwards on the splicing part a4 of that station, undertaking the task of pre-curing at each station. The lower UV lamp 41 is installed on the turntable 21 and rotates synchronously with it. Its relative position to the wax part remains unchanged during the indexing process, always shining upwards from below the wax part, covering the sections that the upper UV lamp 41 cannot reach. The two lamps shine in opposite directions, respectively covering the upper visible surface and the lower backlight surface of the splicing part a4.

[0075] In this embodiment of the invention, the upper ultraviolet lamp 41 and the lower ultraviolet lamp 41 irradiate the splicing part a4 from the upper and lower directions respectively. This reduces the curing blind zone by addressing the issue of unidirectional irradiation forming a light blockage on the blade a3 profile and the inner wall of the outer jacket. Both lamps are controlled by the control host 5, the irradiation time is determined by program parameters, and the irradiation dose can be quantitatively controlled. The lower ultraviolet lamp 41 rotates with the turntable 21 and is fixed in relative position to the wax part. The irradiation conditions below each blade a3 station are consistent, eliminating the need for manual operation.

[0076] In some embodiments, the control host 5 also includes a display screen, and the control circuit can be connected to a host computer to set parameters for different products. The parameters include the number of blades a3, the drip volume, the drip rate, the drip interval, and the irradiation time.

[0077] In this invention, the control circuit in the control host 5 is connected to the host computer, which stores process parameters corresponding to the guide model. The control host 5 controls the number of divisions and division angle of the turntable 21, the dripping time and dripping air pressure of the dripping tube 31 assembly, and the irradiation time of the upper ultraviolet lamp 41 according to the process parameters issued by the host computer.

[0078] Specifically, different models of guide vanes differ in the number of blades (a3), splice length, and required fillet radius. Consequently, the number of indexing operations, indexing angle, dripping time, dripping pressure, and UV lamp irradiation time also vary. These parameters are stored in the host computer using the guide vane model as an index. During production changeovers, the corresponding parameter set is retrieved from the host computer and sent to the control host 5. The control host 5 then operates according to the new parameters, eliminating the need for manual parameter input. The creation and modification of process parameters are performed on the host computer, and the modification history is recorded.

[0079] In one specific embodiment, the production workshop simultaneously accepts orders for multiple models of guides, requiring frequent changes in the production sequence. During product changeover, operators select the target model on the host computer, which then sends the corresponding parameters to the control host 5, completing the changeover parameter switching. Process parameters are centrally managed by process engineers on the host computer, eliminating the need for operators to directly modify control parameters. All parameter changes are recorded and traceable, ensuring process consistency between batches.

[0080] In some embodiments, the dropper 31 is used to store wax-containing photosensitive resin.

[0081] In this invention, the drip tube 31 stores wax-containing photosensitive resin, which is cured under ultraviolet light irradiation. The drip tube 31 serves as a storage and delivery container for the resin, and its inner cavity is connected to the splicing part a4 via the drip head 32. The resin is dripped out through the drip head 32 under air pressure. The drip tube 31 is detachably mounted on the fixed base 37. When the resin is used up, the entire tube can be replaced without adjusting the equipment's air circuit or control circuit. When changing resin batches, if the viscosity changes, it can be compensated for by adjusting the drip air pressure setting without replacing other components.

[0082] It should be noted that the embodiments referred to in the specification, such as "one embodiment," "embodiment," "exemplary embodiment," and "some embodiments," may include specific features, structures, or characteristics, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0083] It should be readily understood that “on,” “above,” and “on top of” in this disclosure should be interpreted in the broadest manner, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on something” but also “on something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0084] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90 degrees or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0085] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0086] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for assembling and molding wax models of complex leaf-shaped guide castings, characterized in that, Includes the following steps: Using the junction of the blade tip of the guide and the inner wall of the outer sleeve as the splitting surface, the guide wax model is split into an inner ring wax part and an outer sleeve wax part. The inner ring wax part has the blade of the guide. The inner ring wax part and the outer sleeve wax part are respectively injection molded. The inner ring wax piece and the outer ring wax piece are positioned and combined, and the inner ring wax piece and the outer ring wax piece are bonded and fixed to obtain a combined wax piece. The blade tips of each blade in the combined wax piece and the inner wall of the outer ring wax piece respectively form splicing parts. Photosensitive resin is dripped onto the splicing area, and the dripped photosensitive resin is photocured to form a rounded corner at the splicing area.

2. The method for assembling and molding wax models of complex leaf-shaped guide castings according to claim 1, characterized in that, The inner ring wax part is removed by unscrewing after wax injection molding, and the outer ring wax part is removed by opening the mold from the top and bottom after wax injection molding.

3. The method for assembling and molding wax models of complex leaf-shaped guide castings according to claim 1, characterized in that, When dripping photosensitive resin onto the splicing part, the combined wax piece is clamped on the turntable (21), and the tilt angle of the turntable (21) is adjusted so that the dripping head (32) located above the turntable (21) does not interfere with the combined wax piece, and the dripped photosensitive resin can flow along the splicing part; the position of the dripping head (32) is adjusted so that the dripping head (32) is directly opposite the tip of the blade at the air intake edge.

4. The method for assembling and molding wax models of complex leaf-shaped guide castings according to claim 3, characterized in that, The number of rotations of the turntable (21) is set according to the number of blades of the guide, and the volume of photosensitive resin for a single drip is set according to the length of the splicing part.

5. The method for assembling and molding wax models of complex leaf-shaped guide castings according to claim 3, characterized in that, After the dripping head (32) completes the dripping of the splicing part corresponding to the current blade, the ultraviolet lamp (41) irradiates the splicing part corresponding to the current blade to preliminarily cure the photosensitive resin therein; The turntable (21) then rotates so that the drip head (32) is aligned with the splicing part corresponding to the next blade and drips.

6. The method for assembling and molding wax models of complex leaf-shaped guide castings according to claim 5, characterized in that, After the splicing parts corresponding to each blade have been dripped and initially cured, the assembled wax parts are placed in an ultraviolet curing chamber for irradiation to completely cure the photosensitive resin at each splicing part.

7. An apparatus for assembling and molding wax models of complex leaf-shaped guide castings, used to implement the method for assembling and molding wax models of guide castings as described in any one of claims 1-6, characterized in that, include: Base (1); The turntable assembly (2) is set on the base (1) and includes a turntable (21) and a servo motor (22) for driving the turntable (21) to rotate. The turntable (21) is provided with a wax fixing fixture (23) for clamping the combined wax parts. The tilt angle of the turntable (21) is adjustable. The drip assembly (3) includes a drip tube (31) and a drip head (32) disposed at the lower end of the drip tube (31). The drip tube (31) is used to store photosensitive resin, and the drip head (32) is located above the turntable (21) so that the photosensitive resin can be dripped out through the drip head (32) under air pressure. The curing component (4) includes an ultraviolet lamp (41) for irradiating the spliced ​​area. The control host (5) is used to control the rotation of the turntable (21), the dripping action of the dripping assembly (3), and the opening and closing of the ultraviolet lamp (41).

8. The equipment for assembling and molding wax models of complex leaf-shaped guide castings according to claim 7, characterized in that, The drip assembly (3) further includes a main support arm (33), a connecting seat (34), and a side arm (35). The main support arm (33) is fixed on the base (1). The connecting seat (34) is vertically mounted on the main support arm (33). The main support arm (33) is provided with a height adjustment component that drives the connecting seat (34) to rise and fall. One end of the side arm (35) is connected to the connecting seat (34), and the other end is provided with a fixed seat (37). The drip tube (31) is mounted on the fixed seat (37).

9. The equipment for assembling and molding wax models of complex leaf-shaped guide castings according to claim 7, characterized in that, The turntable assembly (2) also includes a motor mount (24) disposed on the base (1), and the servo motor (22) is rotatably mounted on the motor mount (24) to adjust the tilt angle of the turntable (21); the motor mount (24) is provided with an angle fixing knob (25) for locking the tilt angle of the turntable (21) and an angle indicator (26) for indicating the tilt angle of the turntable (21).

10. The equipment for assembling and molding wax models of complex leaf-shaped guide castings according to claim 7, characterized in that, The drip assembly (3) also includes a top cover and an air tube. The top cover closes the upper end of the drip tube (31). The control host (5) is equipped with a control circuit, a solenoid valve, a pressure sensor and an air pump. One end of the air tube is connected to the top cover and the other end is connected to the air pump. The air pump supplies air to the drip tube (31) through the air tube. The control circuit adjusts the air pressure in the drip tube (31) through the solenoid valve according to the detection signal of the pressure sensor, so as to control the drip volume and drip speed of the photosensitive resin.

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