Closed Impeller Flow Path Machining for Tight Curvature Regions
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Solution Overview
Problem
The existing methods for manufacturing centrifugal rotary machines struggle to form a desired flow path when the radius of curvature of the flow path is smaller than the opening area of the inlet or outlet, making it difficult to cut the block effectively.
Innovation Solution
A method involving multiple cutting tools, including a rough cutting tool, an intermediate/finishing cutting tool, and a residue-cutting tool, where the residue-cutting tool is designed with a larger maximum outer diameter and a specific blade configuration to cut the remaining residues, allowing for precise cutting even in areas with small radii of curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single cutting tool is used to cut the flow path in the block, then the manufacturing process is simple, but it is impossible to form a desired flow path when the radius of curvature is smaller than the opening area of the inlet or outlet
Solution Approach 1:
The patent divides the flow path cutting process into multiple stages using different cutting tools: a first cutting tool for rough cutting with larger diameter, and a second cutting tool for residue cutting with smaller diameter. This segmentation allows each tool to be optimized for its specific function, enabling the formation of flow paths with small radii of curvature that cannot be achieved with a single tool
2Productivity
If a rough cutting tool with large diameter is used, then it can efficiently remove material, but it cannot cut residues in areas with small radii of curvature
Solution Approach 1:
The patent segments the cutting function between two tools: the first cutting tool handles bulk material removal with high efficiency, while the second cutting tool handles residue removal in tight spaces. This division allows the system to achieve both high productivity and precise finishing
3Manufacturing precision
If a cutting tool with small diameter is used, then it can access areas with small radii of curvature, but the opening area of the inlet or outlet becomes larger relative to the tool size
Solution Approach 1:
The patent applies preliminary action by using the first cutting tool to perform rough cutting and create a preliminary flow path shape before using the second cutting tool. This preliminary action removes the bulk of the material, allowing the second tool to focus on precise residue removal without being constrained by the large opening area
Data Source
AI summary
When a closed type impeller is manufactured from one block, a rough cutting process of cutting a flow path region of a block using a rough cutting tool, and a residue-cutting process of cutting a cutting residue in the cutting process using a residue-cutting tool are executed. The residue-cutting tool has a tool main body having a blade formed on an outer periphery thereof, and a handle having the tool main body fixed to a distal end thereof. A maximum outer diameter of the tool main body is larger than a minimum outer diameter of the handle. Further, the tool main body has a rear blade directed in a direction including a tool rear side component.