Rotary Machine Component Inner Channel Build-Up Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing components with inner channels in rotary machines, such as impellers and guide wheels, face geometrical limitations that make whole-machine machining impractical, leading to inefficiencies and potential defects in casting or high costs with eroding methods.
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 complex geometries and avoiding the limitations of traditional machining or casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining manufacturing is used for components with complex inner channels, then manufacturing precision and surface quality are improved, but the method becomes impractical due to geometrical limitations
Solution Approach 1:
The manufacturing process is divided into two distinct segments: a subtractive machining phase for creating the basic component structure and accessible channel portions, and an additive build-up phase for completing complex channel geometries. This segmentation allows each method to be applied where it is most effective, overcoming the geometrical limitations of pure machining while maintaining precision where possible.
Solution Approach 2:
The invention changes the manufacturing approach parameter from exclusively subtractive (machining) to a combined subtractive-additive process. This parameter change enables the creation of complex inner channel geometries that would be inaccessible to machining tools alone, while still utilizing machining for high-precision surface areas.
2Shape
If casting is used to manufacture components with inner channels, then complex geometries are achieved, but defects arise in structural conditions reducing resilience and stability
Solution Approach 1:
The component manufacturing is segmented into phases: casting is used only for creating the basic complex outer geometry and inaccessible inner channel regions, while subtractive machining is applied to critical structural areas and channel portions requiring high structural integrity. This segmentation eliminates casting defects from load-bearing areas while retaining the ability to manufacture complex geometries.
Solution Approach 2:
Different manufacturing qualities are applied to different regions of the component: high-precision machining is applied to areas requiring structural strength and surface quality, while casting is used for regions where complex geometry is the primary requirement. This local quality approach ensures that each area of the component has the optimal properties for its specific function.
3Ease of manufacture
If eroding methods like EDM are used for manufacturing inaccessible channel areas, then manufacturing capability is improved, but the process becomes slow and expensive
Solution Approach 1:
Instead of using expensive eroding methods for the entire component, the invention applies machining (a faster, more economical method) to the extent that geometrical constraints allow, and only uses additive build-up processes for the specific portions of channels that are truly inaccessible to machining. This partial application of methods optimizes both capability and productivity.
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.