Rotating Spindle Additive Manufacturing for Impeller Curved Surfaces
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Solution Overview
Problem
Existing additive manufacturing methods face difficulties in forming complex curved surfaces within impellers due to limitations in moldability, particularly when trying to shape parts with specific inclinations, which can lead to challenges in forming other parts effectively.
Innovation Solution
The method involves rotating a spindle to form powder layers radially while irradiating specific areas with a beam, allowing for the sequential lamination of metal layers to create complex shapes like impellers, with options for adjusting the rotation angle and material viscosity to prevent material flow and ensure seamless melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is performed by laminating metal from lower side to upper side, then the manufacturing process is simple, but it is difficult to form complicated curved surfaces with specific inclination angles
Solution Approach 1:
The invention applies dynamics by rotating the workpiece on a spindle during additive manufacturing. Instead of keeping the workpiece stationary and moving the deposition head in complex trajectories, the workpiece rotates dynamically, allowing the beam to deposit material along the circumferential direction while the workpiece itself provides the rotational motion. This dynamic approach enables formation of complicated curved surfaces and three-dimensional shapes that would be difficult to achieve with static lamination methods.
2Manufacturing precision
If the attitude of the impeller is inclined to form a specific part, then that part can be shaped accurately, but it becomes difficult to form other parts
Solution Approach 1:
The invention achieves universality through the rotating spindle configuration that can accommodate and shape the entire impeller structure in one setup. The workpiece is fixed to the spindle and rotates, allowing the beam to access and deposit material on different parts of the impeller (blades, disk, cover) sequentially during rotation. This multi-functional approach eliminates the need to reposition or re-incline the workpiece for different parts, enabling formation of the complete complex impeller geometry with complicated curved surfaces in a single manufacturing process.
3Manufacturing precision
If the spindle rotates over a large angle, then material coverage is improved, but seams appear between irradiation ranges
Solution Approach 1:
The invention applies partial action by rotating the workpiece through a small angle (10 degrees or less) during beam irradiation rather than completing a full rotation. The beam irradiates a prescribed area of the powder layer while the workpiece rotates slightly, creating overlapping irradiation ranges that ensure complete material coverage without gaps. This partial rotational approach prevents seams between irradiation zones while maintaining uniform material distribution, as the small rotation angle ensures that the beam covers the entire deposition area multiple times during the manufacturing cycle.
4Ease of operation
If shaping material with low viscosity is used, then material flow is easier, but material flows downward in vertical direction during spindle rotation
Solution Approach 1:
The invention applies parameter changes by carefully controlling the viscosity of the shaping material to be within a prescribed range that balances flowability and position stability. The material must have sufficient fluidity to be deposited and spread evenly on the rotating workpiece surface, but not so fluid that it flows downward under gravity during rotation. By optimizing this physical parameter (viscosity), the process achieves both easy material operation and precise positional control during the additive manufacturing process.
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 moldability of complex shapes by enabling the formation of impellers with intricate designs, such as those with curved surfaces and varying diameters, while maintaining uniformity and reducing anisotropy in strength distribution.
Implementation Method 1
a beam irradiating step of solidifying the shaping material by irradiating a prescribed area of the powder layer with a beam
Implementation Method 2
forming a powder layer by feeding a shaping material which includes a metal powder onto a base which is provided outside a spindle in a radial direction thereof while rotating the spindle
Data Source
AI summary
An additive manufacturing method includes forming a shaped body by repeating: a material feeding step of forming a powder layer by feeding a shaping material that includes a metal powder onto a base that is provided outside a spindle in a radial direction thereof while rotating the spindle provided to be rotatable about a center axis; and a beam irradiating step of solidifying the shaping material by irradiating a prescribed area of the powder layer with a beam.