Compressor Impeller Cutting Strategy for Residual Strain Reduction
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Solution Overview
Problem
Conventional manufacturing methods for compressor impellers result in residual strain at the center portion due to successive cutting of inter-vane regions, leading to uneven weight distribution and potential noise or vibration issues in turbochargers.
Innovation Solution
A manufacturing method that involves cutting inter-vane regions while avoiding adjacent regions as often as possible, positioning cuts diagonally or in pairs, and dividing regions into groups to minimize residual strain, ensuring balanced weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inter-vane regions are cut successively in the circumferential direction while pressing the workpiece, then the cutting process can be completed efficiently, but residual strain accumulates at the center portion causing uneven weight distribution and potential noise or vibration
Solution Approach 1:
The cutting process is segmented into multiple passes with different cutting patterns. Instead of cutting all inter-vane regions in one sequential pass, the method divides the cutting into first and second patterns where adjacent regions are avoided in consecutive cuts. This segmentation prevents strain accumulation while maintaining productivity.
Solution Approach 2:
The method performs preliminary cutting actions in a specific sequence that anticipates and prevents strain accumulation. By cutting non-adjacent inter-vane regions first and leaving adjacent regions for later cuts, the workpiece center maintains its position stability throughout the process, preventing residual strain before it occurs.
2Ease of manufacture
If adjacent inter-vane regions are cut successively, then the manufacturing process is simple and fast, but the center portion of the workpiece inclines and accumulates strain
Solution Approach 1:
The cutting process dynamically adjusts the cutting sequence based on the workpiece state. The method switches between first and second cutting patterns depending on which regions have been previously cut, ensuring that adjacent regions are never cut consecutively. This dynamic adjustment maintains center portion stability throughout the manufacturing process.
3Manufacturing precision
If cutting order is optimized to avoid adjacent regions, then residual strain is reduced, but cutting time may increase
Solution Approach 1:
The cutting process uses periodic alternation between first and second cutting patterns. After cutting certain regions in the first pattern, the method periodically switches to the second pattern to cut remaining regions. This periodic action ensures optimal strain reduction while maintaining efficient cutting cycle time by systematically covering all regions without unnecessary delays.
Data Source
AI summary
An object is to provide a manufacturing method of a compressor impeller which produces a small post-cutting residual strain. A compressor impeller is formed by cutting a workpiece. The manufacturing method of a compressor impeller includes: a workpiece-fixing step of fixing a workpiece W on the supporting pedestal 3; and a cutting step of cutting inter-vane regions R and forming a plurality of vane sections B1, B2 and so on with intervals between one another in the circumferential direction of the workpiece W while pressing the workpiece. The cutting step includes selecting one of following steps. In the first cutting step, when successively cutting the plurality of inter-vane regions R1, R2 and so on disposed continuously in the circumferential direction of the workpiece, adjacent one of the inter-vane regions is avoided as often as possible. In the second cutting step, when simultaneously cutting a part of the plurality of inter-vane regions R1, R2 and so on which includes more than one of the inter-vane regions disposed continuously in the circumferential direction of the workpiece, at least one of the part of the plurality of inter-vane regions being cut simultaneously is positioned away from other inter-vane regions being cut simultaneously by a distance of one or more inter-vane regions as often as possible.