Rotary Machine Component Repair With Machined-Then-Built Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing components with inner channels in rotary machines are limited by geometrical constraints, making it impractical to machine these channels as a whole, leading to inefficiencies and potential defects in components like closed impellers, guide wheels, and diffusers.
Innovation Solution
A method combining subtractive and additive processes, where a part of the channel is machined and the rest is built up using a build-up process, allowing for the creation of channels with complex geometries without the need for assembly or casting, using a blank with a smaller radial dimension than the finished component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a component with inner channels is manufactured by casting, then complex geometries can be achieved, but defects arise in structural conditions reducing resilience and stability
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: first, machining the blank to create initial channel structures from solid material; second, using a build-up process to complete the channel geometries. This segmentation allows each process to address its strengths while avoiding its weaknesses, eliminating casting defects while achieving complex shapes.
Solution Approach 2:
The blank is pre-machined to create a foundation structure with preliminary channel forms before the build-up process. This preliminary action establishes the basic geometry and material integrity, allowing the subsequent build-up process to add complex features without compromising structural reliability.
2Reliability
If a component is machined as a whole out of solid material, then integral structure without welding seams is achieved, but geometrical constraints make this impossible for closed impellers
Solution Approach 1:
The manufacturing process is divided into machining of a blank and subsequent build-up processing. This segmentation enables the creation of closed impeller geometries that would be impossible to machine as a whole, while still maintaining integral structure by building up material directly on the machined blank without requiring separate parts or welding.
Solution Approach 2:
The invention changes the manufacturing approach from purely subtractive machining to a combination of subtractive machining and additive build-up. This parameter change in the manufacturing process enables the production of closed impeller geometries with integral structures that cannot be achieved by traditional machining alone.
3Shape
If channels are manufactured by eroding methods like EDM, then complex geometries are achieved, but the process is slow and expensive
Solution Approach 1:
The manufacturing process segments channel creation into two parts: machining the accessible portions from the blank exterior surfaces, and using build-up process for the remaining complex geometries. This segmentation avoids the need for slow eroding methods like EDM while still achieving complex channel shapes, significantly improving productivity.
Solution Approach 2:
The blank is pre-machined to create channel portions that are accessible from exterior surfaces before the build-up process. This preliminary machining action removes material efficiently rather than adding it slowly through erosion, dramatically reducing manufacturing time and cost for the accessible channel portions.
4Length of stationary object
If a blank with smaller radial dimension is used, then the final build-up component achieves larger radial dimension, but requires combination of subtractive and additive processes
Solution Approach 1:
The manufacturing process is segmented into subtractive machining of the blank and additive build-up of the final geometry. This segmentation enables the transition from a smaller blank to a larger final component, achieving the required radial dimension while managing process complexity through clear separation of operations.
Solution Approach 2:
The invention changes the net material removal approach to a combination of material removal and material addition. By using a blank with smaller radial dimension and building up material selectively, the process achieves larger final radial dimensions while maintaining control over geometry and properties through the build-up process parameters.
Data Source
AI summary
A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction. A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.