Pressurized Jet Removal of Additive Support Structures
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Solution Overview
Problem
The removal of support structures in additive manufacturing of complex vaned components for turbomachines is time-consuming and costly, especially for poorly accessible areas, limiting the efficiency and quality of the manufacturing process.
Innovation Solution
A method and apparatus that include additively manufacturing vaned components with support structures having predetermined breaking points, allowing for the use of a pressurized jet to break and remove these structures efficiently, reducing the need for manual labor and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual removal methods are used for support structures in additive manufacturing, then the support structures can be removed from complex components, but the process becomes extremely time-consuming and costly
Solution Approach 1:
The support structures are designed with predetermined breaking points during the additive manufacturing process. These breaking points are created in advance with reduced material density or structural weakness, enabling automatic breakage when exposed to the pressurized jet, thereby eliminating the need for time-consuming manual removal operations
Solution Approach 2:
The manual mechanical removal process (using screwdrivers, tongs, hammers, hand milling cutters, hand grinders) is replaced by a pressurized jet system. The jet applies fluid pressure to the support structures, causing them to break at the predetermined breaking points automatically, substituting mechanical hand operations with a automated fluid-based system
Solution Approach 3:
A pressurized jet (fluid stream under high pressure) is used to remove the support structures. The pressurized fluid targets the predetermined breaking points of the support structures, causing them to fracture and detach from the component. This pneumatic/hydraulic approach replaces manual mechanical tools and significantly reduces removal time
2Reliability
If support structures are used to stabilize over-hanging areas during additive manufacturing, then the component can be built successfully, but the support structures must be removed after completion
Solution Approach 1:
The support structures are designed with predetermined breaking points during the additive manufacturing process. These breaking points are created in advance with reduced material density or structural weakness, enabling automatic breakage when exposed to the pressurized jet, thereby eliminating the need for time-consuming manual removal operations
Solution Approach 2:
The manual mechanical removal process (using screwdrivers, tongs, hammers, hand milling cutters, hand grinders) is replaced by a pressurized jet system. The jet applies fluid pressure to the support structures, causing them to break at the predetermined breaking points automatically, substituting mechanical hand operations with a automated fluid-based system
Solution Approach 3:
A pressurized jet (fluid stream under high pressure) is used to remove the support structures. The pressurized fluid targets the predetermined breaking points of the support structures, causing them to fracture and detach from the component. This pneumatic/hydraulic approach replaces manual mechanical tools and significantly reduces removal time
3Productivity
If the support structures are designed with predetermined breaking points, then the pressurized jet can efficiently remove the support structures, but the support structures require special design considerations
Solution Approach 1:
The support structures are designed with local variations in material properties. Specifically, predetermined breaking points are created with reduced material density or structural weakness at specific locations along the support structures. This local quality change allows the support structures to be strong where needed while having predetermined weak points for easy breakage during removal
Solution Approach 2:
The support structures are designed with predetermined breaking points during the additive manufacturing process. These breaking points are created in advance with reduced material density or structural weakness, enabling automatic breakage when exposed to the pressurized jet, thereby eliminating the need for time-consuming manual removal 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
This approach significantly reduces the time and cost associated with support structure removal, enhancing the efficiency and quality of the manufacturing process by enabling faster and more precise removal of support structures from complex components.
Implementation Method 1
applying a pressurized jet to the plurality of support structures, thereby breaking the predetermined breaking points of the plurality of support structures and removing the plurality of support structures
Implementation Method 2
applying a pressurized jet to the plurality of support structures, thereby breaking the predetermined breaking points
Data Source
AI summary
A method for manufacturing a vaned component of a turbomachine is provided. The method includes providing a base portion, additively manufacturing, on top of the base portion, a plurality of vanes and a plurality of support structures, the plurality of support structures having predetermined breaking points, additively manufacturing, on top of the plurality of support structures and the vanes, a top portion being supported by the plurality of support structures, whereby the vanes are sandwiched between the base portion and the top portion, and applying a pressurized jet to the plurality of support structures, thereby breaking the predetermined breaking points of the plurality of support structures and removing the plurality of support structures.