Net-Shape Sintered Vane for Rotary Pump
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Solution Overview
Problem
The production of vane pumps involves complex and costly processes that require significant post-processing to achieve the necessary tolerances and surface finishes, leading to inefficiencies and increased costs.
Innovation Solution
A method for producing a net-shape vane made of metallic sintered material using a process that includes pressing a powder mixture into a green compact, sintering to form an austenitic structure, quenching to harden, tempering, and removing the vane as a net-shape product without the need for further machining, utilizing a sintering furnace for all heat treatments and potentially incorporating open-pored surfaces for improved lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining processes are used to produce vane components, then precise tolerances and surface finishes can be achieved, but the production process becomes complex and costly with significant post-processing requirements
Solution Approach 1:
The invention changes the material state from conventional metal to metallic powder, and changes the manufacturing process from mechanical machining to sintering. By controlling sintering parameters (temperature, pressure, atmosphere) and subsequent heat treatment parameters (quenching temperature, tempering time), the process achieves precise dimensional tolerances and desired microstructures without complex machining operations
Solution Approach 2:
The invention utilizes phase transitions of metallic powders during sintering (from loose powder to compacted green body to sintered part) and during heat treatment (austenite to martensite transformation during quenching). These controlled phase transitions enable the material to achieve final dimensions and microstructures directly, eliminating the need for post-processing machining
2Manufacturing precision
If conventional machining processes are used to produce vane components, then required tolerances can be achieved, but production time and costs increase due to extensive post-processing
Solution Approach 1:
The invention performs preliminary shaping and dimensional formation during the sintering process itself, creating near-net-shape or net-shape components that require minimal or no post-processing. The green compact is formed with precise dimensions before sintering, and the sintering process maintains these dimensions with minimal shrinkage, eliminating the need for subsequent machining operations and significantly improving production efficiency
Solution Approach 2:
The invention replaces mechanical machining operations with thermal-sintering processes. Instead of using cutting tools and mechanical forces to remove material and achieve tolerances, the process uses controlled heating, pressing, and phase transformations to form the final component geometry directly, thereby eliminating time-consuming post-processing steps
3Ease of manufacture
If traditional sintered materials are used, then manufacturing is simplified, but lubrication performance is insufficient without additional surface treatments
Solution Approach 1:
The invention utilizes the inherent porosity of sintered metallic materials as a functional feature for lubrication. The interconnected pore structure within the sintered component allows lubricant to be absorbed, retained, and distributed throughout the component, providing continuous lubrication without requiring additional surface treatments or coatings. This transforms a potential weakness (porosity) into a functional advantage for lubrication
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 method simplifies the production of vanes by eliminating the need for post-processing, achieving precise tolerances and surface finishes directly, and enhancing lubrication through open-pored surfaces, thereby reducing production costs and improving vane performance.
Implementation Method 1
Pressing a powder mixture into a green compact using a powder press
Implementation Method 2
Sintering the green compact within a sintering furnace to form a sintered part with an austenitic microstructure
Implementation Method 3
Sintering the green compact within a sintering furnace to form a sintered part with an austenitic microstructure
Implementation Method 4
Quenching the sintered part within the sintering furnace to a temperature below the martensite start temperature of the sintered part to harden the sintered part
Implementation Method 5
Tempering the sintered part
Data Source
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AI summary
The invention relates to a method for producing a net-shape vane for a rotary vane pump, which vane is preferably open-pored and consists of a metal sinter material. The vane has at least one first front face and one second front face which is preferably oriented parallel to the first front face, and a first lateral surface and second lateral surface that is oriented parallel to the first lateral surface. Furthermore, the vane comprises a first contour surface and a second contour surface. The method for producing the vane comprises at least the following steps: pressing (20) a powder mixture to a green body by means of a powder press, sintering (21) the green body inside a sintering furnace to a sintering element having an austenitic structure, quenching the sintering element inside the sintering furnace to a temperature below the martensitic start temperature for hardening (22), tempering (23) the sintering element preferably inside the sintering furnace, removing (24) the sintering element as net-shape vane, preferably as removal from the sintering furnace. After removing the sintering element, deburring (25) can optionally be made. The invention further relates to a vane and a rotary vane pump.