Refiner Disc Segment Production via 3D Printed Investment Casting
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Solution Overview
Problem
The manufacturing of refiner discs for disc-type refiners is inefficient due to high wear of die surfaces during sand compression and limitations in creating complex segment patterns with traditional machining methods, which affects the quality and longevity of refiner segments.
Innovation Solution
A method involving 3D printing to produce refiner segments using a combination of low-melting-point materials for initial models, followed by casting with high-melting-point metals for durability and subsequent sand models, allowing for the creation of complex surface structures with reduced wear and increased production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sand model fabrication process is used, then refiner segments can be produced, but die surface wear is high during sand compression
Solution Approach 1:
The patent uses 3D printing to create a master model that is then used to fabricate the die. This copying approach allows the die to be made from materials optimized for compression resistance rather than requiring the master model itself to withstand compression, thereby reducing die surface wear and extending service life.
Solution Approach 2:
The patent changes the material parameters of the die by selecting materials with high compression resistance and appropriate hardness for the die, while the 3D printed master model can use different materials optimized for printing. This parameter change resolves the contradiction between producing functional segments and maintaining die durability.
2Adaptability or versatility
If traditional machining methods are used, then refiner segments can be manufactured, but complex segment patterns cannot be created
Solution Approach 1:
The patent replaces traditional mechanical machining methods with 3D printing technology for creating the master model. This substitution enables the fabrication of complex segment patterns, dams, and openings that would be difficult or impossible to create with conventional machining, while actually simplifying the manufacturing process by adding rather than subtracting material.
Solution Approach 2:
The patent utilizes the third dimension in 3D printing to create complex internal structures, curved surfaces, and multi-level features in the segment patterns. This dimensional capability allows for sophisticated refiner segment designs that control material flow and processing in ways not achievable with traditional 2D machining approaches.
3Adaptability or versatility
If 3D printing is used to create models, then complex designs are enabled, but additional processing steps are required
Solution Approach 1:
The patent performs preliminary actions by 3D printing the master model with all desired segment patterns, dams, and openings already incorporated into the design. This preliminary creation of the complete pattern set eliminates the need for subsequent complex machining operations to create these features, as they are built in during the printing process itself.
Solution Approach 2:
The 3D printed master model serves as an intermediary between the digital design and the final refiner segments. It translates the complex digital geometry into a physical form that can be used to create molds or patterns for segment production, bridging the gap between design flexibility and manufacturable components.
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 enables the production of refiner segments with improved surface structure quality and increased longevity, allowing for more complex designs and reduced manufacturing costs by minimizing wear on the die surfaces and overcoming limitations of traditional machining.
Implementation Method 1
3D printing a first model
Implementation Method 2
molding or casting with a first metal material having a first melting point a first inner die part using the first part mold
Implementation Method 3
casting a refiner disc segment by casting a metal material using the sand model
Data Source
AI summary
The disclosure relates to a method for producing of refiner disc segments. The method for producing of the invention allows for forming a multitude of refiner segments with only one forming process of a first die which may be lightweight and has reduced cost while at the same time a surface structure with high hardness which reduces wear of the die's surface. The method for producing a disc-type refiner segment for refining lignocellulosic material includes 3D printing a first model; forming a first die part using investment casting; 3D printing a second model; combining the first die part and the second model to create a first die model; using the first die model to generate for forming a sand model by compressing molding sand between the first die and the second die; and casting a refiner disc segment by casting a metal material using the sand model.