Airfoil Platform Core Design for Cooling Passage Formation
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Solution Overview
Problem
Existing methods for molding airfoil platforms with lost core techniques require additional machining steps to form side openings for cooling air passages, increasing manufacturing complexity and time.
Innovation Solution
A method involving a main body core and a platform core with side portions that form side openings, allowing molten metal to solidify around the cores and eliminating the need for post-molding machining by creating cavities and openings during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lost core molding technique is used to form cooling passages, then cooling air can be circulated within passages, but additional machining steps are required to form side openings
Solution Approach 1:
The platform core is designed with side portions that extend laterally to form side openings during the molding process itself, eliminating the need for post-molding machining. The core configuration includes lateral extensions that directly create the required openings as the metal solidifies around it.
Solution Approach 2:
The invention combines the formation of both the main cooling passages and side openings into a single molding operation. By integrating the side opening formation into the core design, multiple features are created simultaneously rather than through separate machining steps.
2Ease of manufacture
If traditional lost core technique with main body core is used, then openings can be formed, but post-molding machining is required to complete side openings
Solution Approach 1:
The side openings are pre-formed during the molding process through the lateral extensions of the platform core, so that no additional machining time is required after molding. The core configuration anticipates the final geometry requirements and creates openings in advance.
3Ease of operation
If cores are extended upwardly beyond top surface to form openings, then access points are created for EDM, but large surface area is required for machining
Solution Approach 1:
Instead of extending cores vertically to create top surface openings for machining access, the invention extends the platform core laterally in the horizontal dimension. This creates side openings that provide direct access to cooling passages without requiring large top surface areas for EDM operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the manufacturing process by eliminating the need for post-molding machining of side openings, reducing the surface area required for electro-discharge machining and enhancing the efficiency of cooling air passage formation.
Implementation Method 1
Molten metal is directed around the cores within a mold and solidifies
Implementation Method 2
The cores are dissolved or leached, leaving cavities within the final part
Data Source
Figure 1A
Figure 1B
Figure 1C~3B
AI summary
A method of molding a platform opening includes the steps of providing a main body core (36) and a platform core (34), with the main body core (36) having a portion that forms a portion of the platform. The platform core (34) has at least one side portion (46) that will form a side opening (11). Molten metal is directed around the cores (34,36) within a mold (130) and solidifies. The cores (34,36) are removed, leaving cavities where the cores (34,36) were within the molten metal, and includes an opening (11) in a side face formed by the side portion (46) of the platform body core (34).