Turbomachine Rotor Vane Inclined Seal Casting Method
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Solution Overview
Problem
Current methods cannot produce rotor blades with inclined knife-edge seals connected by a web of material, as the casting mould must be moved parallel to the blade's longitudinal axis for demoulding, which is not feasible for anisotropic materials like nickel-based alloys.
Innovation Solution
A method involving a blank casting with a downstream knife-edge seal having a transverse machining allowance, allowing the mould to be removed along the longitudinal axis, and subsequent machining to incline the seal, enabling the use of simple casting tools and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the downstream knife-edge seal is cast with an inclined upstream face to improve sealing, then gas leak reduction is improved, but the mould cannot be removed by translation along the longitudinal axis
Solution Approach 1:
The patent applies preliminary action by providing a transverse machining allowance on the downstream knife-edge seal before final machining. This allowance is prepared in advance during casting, enabling the mould to be removed by translation along the longitudinal axis, while the subsequent machining step creates the required inclined upstream face for effective sealing.
2Ease of manufacture
If the downstream knife-edge seal is cast straight (parallel to longitudinal axis) to enable simple mould removal, then ease of manufacture is improved, but sealing effectiveness deteriorates
Solution Approach 1:
The patent resolves this contradiction by performing preliminary casting with a straight downstream knife-edge seal that includes a transverse machining allowance, enabling simple mould removal by translation. The inclined upstream face is then created in a subsequent machining step, ensuring both ease of manufacture and sealing effectiveness are achieved.
3Reliability
If inclined knife-edge seals are produced by casting to improve sealing, then gas leak reduction is improved, but additional machining steps are required
Solution Approach 1:
The patent reduces manufacturing process complexity by providing the transverse machining allowance during the initial casting step. This preliminary preparation allows the downstream knife-edge seal to be cast in the correct position and orientation, requiring only a single machining operation to create the inclined upstream face, rather than multiple complex machining steps.
Data Source
AI summary
A method for producing a rotor vane (10) for a turbomachine, including producing a rough casting, the heel of which has a downstream lip (121) with a transverse increased thickness (130) such that the lip has an upstream surface (134) substantially parallel to an axis The method further includes machining said increased thickness so that the downstream lip has an upstream surface (138) inclined in relation to the axis.