Wax Injection Mold with Motorized Arcuate Cavity Blocks
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Solution Overview
Problem
Existing molds for manufacturing turbine engine blades using the lost-wax casting technique face issues such as horizontal layout leading to tool damage, manual handling difficulties, and high risk of model deformation or breakage due to manual removal, which results in costly repairs and reduced production efficiency.
Innovation Solution
A mold design with movable cavity blocks driven by a motorized mechanism, allowing for arcuate movement to follow the cylindrical profile of the blade and incorporating an ejector system for automated part removal, reducing manual handling and improving operational safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mold is placed on a horizontal plane with horizontal orientation of the impression, then the injection process is simplified, but the cavity becomes vulnerable to tool blows and marks causing costly repairs and production stoppage
Solution Approach 1:
The invention inverts the conventional horizontal mold orientation by positioning the cavity vertically. This allows the operator to work from above, applying force in the direction of gravity rather than against it, eliminating the vulnerability to lateral tool blows while maintaining ease of operation
Solution Approach 2:
The invention transitions from a horizontal two-dimensional working plane to a vertical three-dimensional configuration. The cavity is oriented vertically with the operator working from above, changing the spatial dimension of operation to eliminate harmful lateral forces while preserving operational simplicity
2Adaptability or versatility
If manual handling and removal of the wax model is performed, then flexibility is maintained, but the model may deform or break and handling becomes difficult due to weight
Solution Approach 1:
The invention implements self-service by incorporating an integrated ejector system within the mold that automatically removes the wax model after injection. The ejector mechanically pushes the model out of the cavity, eliminating the need for manual handling and preventing deformation or breakage while maintaining operational flexibility
Solution Approach 2:
The ejector system acts as an intermediary between the mold and the wax model during removal. This intermediate mechanism facilitates model extraction without direct operator contact, preventing hand-induced deformation while maintaining the flexibility of the molding process
3Manufacturing precision
If the mold has many elements and sub-parts to allow complete impression formation, then the model quality is improved, but the design and production time increases significantly
Solution Approach 1:
The invention applies segmentation by dividing the cavity into multiple removable blocks that can be independently manufactured and assembled. This allows complex impressions to be created through modular components rather than requiring a single monolithic mold piece, maintaining model quality while reducing overall design and production time
Solution Approach 2:
The cavity blocks are designed with universal features allowing them to be reused for different molding operations. The standardized block design enables multiple blocks to work together in various configurations, reducing the need for custom-designed unique components and thereby reducing design time while maintaining precision
4Device complexity
If the cavity blocks are moved manually, then device complexity is reduced, but the weight makes opening difficult and requires multiple operations increasing time consumption
Solution Approach 1:
The invention replaces manual mechanical handling with an automated ejector mechanism driven by a motor or hydraulic system. This substitution eliminates the need for operators to manually move heavy cavity blocks, significantly increasing opening speed and productivity while reducing the complexity of manual coordination
Solution Approach 2:
The invention introduces dynamic automation through a motorized or hydraulic ejector system that can rapidly actuate the cavity blocks. This dynamic system replaces static manual operation, enabling fast opening and closing cycles that improve productivity without requiring complex multi-step manual procedures
Data Source
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AI summary
The invention relates to a mould for producing a part (20), such as a turbomachine blade model, by injecting wax into a cavity, the cavity consisting of at least two cavity elements, each of which is supported in a cavity block (6, 11). The two cavity blocks are mobile relative to one another between a closed position for injecting the wax and an open position for removing the part following the injection of the wax. The mould is characterised in that the two cavity blocks (6, 11) are mobile in a horizontal plane.