Rotary Machine Component Passages Built by Machining and Build-Up

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Solution Overview

Problem

The challenge lies in manufacturing rotary machine components with inner passages that cannot be fully cut due to geometrical constraints, leading to potential joining defects and reduced load capacity, especially in components like closed impellers and stators where total cutting is impractical.

Innovation Solution

A method combining subtractive machining to create openings and cut-outs with build-up production to complete the passages, allowing for complex geometries and high load-bearing regions to be manufactured with precision without heat-induced defects, using a combination of milling and additive processes like laser build-up welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If total cutting manufacture is used to manufacture rotary machine components with inner passages, then manufacturing precision and reliability are improved by avoiding joining defects, but geometric constraints make total cutting manufacture impossible for closed impellers and stators

Engineering Contradiction:

Improvepassage geometry precisionVSAvoidmanufacturability of closed passages

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into two distinct phases: subtractive machining for high-precision regions (openings and cut-outs) and build-up production for completing the passages. This segmentation allows each process to be optimized for its specific function, resolving the contradiction between precision and manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of the conventional approach of complete subtractive machining or complete molding, the invention inverts the traditional sequence by first performing subtractive machining to create precise openings and cut-outs, then completing the passages through build-up production. This inverted sequence enables both high precision in critical regions and geometric flexibility.

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If conventional molding processes are used to manufacture components with inner passages, then geometric flexibility is improved, but surface quality and dimensional accuracy are reduced

Engineering Contradiction:

Improvegeometric flexibilityVSAvoidsurface quality and dimensional accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Different manufacturing qualities are applied to different regions of the component: subtractive machining provides high surface quality and dimensional accuracy for openings and cut-outs, while build-up production provides geometric flexibility for completing the passages. This local differentiation resolves the contradiction between geometric flexibility and manufacturing precision.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If welding is used to join top plate to hub plate or blades, then component assembly is achieved, but heat-induced defects and joining defects reduce reliability in high-load regions

Engineering Contradiction:

Improveassembly capabilityVSAvoidload capacity and stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention replaces the thermal welding process with a mechanical build-up production process. This substitution eliminates heat-induced defects and joining defects while maintaining the ability to assemble and complete the component geometry, thereby improving reliability in high-load regions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The manufacturing approach changes from thermal process (welding) to mechanical process (build-up production). This parameter change in the manufacturing method eliminates the harmful thermal effects while achieving the same functional result of completing the component assembly.

Inventive Principle:

Principle #35Parameter changes

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 enhances the mechanical load capacity and stability of high-strain regions by maintaining the advantages of forged materials while avoiding welding-related defects, ensuring high reliability and precision in components like impellers and stators.

Implementation Method 1

using a combination of milling and additive processes like laser build-up welding

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

A first subtractive machining step is carried out in which a part of the passage that at least comprises an opening of the passage into the boundary surface as well as a cut-out in the top surface is manufactured by cutting production

Methodology Applied

Scientific EffectMechanical cutting:

Data Source

PatentUS12090569B2Method of manufacturing a component of a rotary machine and component manufactured using said method

Publication Date: 2024.09.17 SULZER MANAGEMENT AG

AI summary

A component of a rotary machine formed from a blank, the component includes a center, a boundary surface, and at least one inner passage extending from the center up to the boundary surface and being at least partly closed. The inner passage is formed by a first subtractive machining in which a part of the passage that at least includes an opening of the passage into the boundary surface as well as a cut-out in the top surface is manufactured by machining production, and subsequently the passage is completed by a build-up production on the blank.