Welded Multi-Process Casing Fabrication for Shorter Lead Time
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Solution Overview
Problem
The existing manufacturing methods for casings in rotating machines, such as steam turbines, require extensive time due to the need for large molds and multiple steps, including casting and welding, which prolongs the design-to-manufacturing process.
Innovation Solution
A manufacturing method that involves forming a casing by welding multiple metal members, which are produced using various methods like forging, steel plate processing, and fused metal deposition, allowing for the reduction of mold-related labor and costs, and enabling faster production by using different materials for different parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single large mold is used for casting the entire casing, then the casing can be formed as an integral structure, but it takes a lot of time to manufacture the large mold and prolongs the design-to-manufacturing period
Solution Approach 1:
The casing is divided into multiple separate block materials instead of being formed as a single integral piece. Each block material can be manufactured independently using smaller molds or alternative processes like forging or steel plate processing, eliminating the need for a single large mold and significantly reducing the design-to-manufacturing time while still achieving the desired integral structure through welding.
Solution Approach 2:
The invention uses multiple different manufacturing methods (casting, forging, steel plate processing, fused metal deposition) to create block materials with different material properties and structures. These composite block materials are then welded together to form the final casing, allowing optimization of each section for its specific functional requirements while reducing overall manufacturing time.
2Volume of stationary object
If the casing is divided into multiple block materials manufactured separately and welded together, then the mold size is reduced, but it still requires preparation of molds and multiple manufacturing steps
Solution Approach 1:
The casing is segmented into multiple block materials that can be manufactured using smaller molds or mold-less processes. This segmentation allows each block to be produced independently with simplified tooling requirements, reducing the volume of molds needed while the welding process integrates them into a unified structure.
Solution Approach 2:
The invention changes the manufacturing parameters by introducing multiple different manufacturing methods (casting, forging, steel plate processing, fused metal deposition) for different block materials. This allows optimization of manufacturing time and mold usage for each specific block based on its geometric and material requirements, rather than using a uniform approach for the entire casing.
3Strength
If traditional casting methods are used for the entire casing, then high-strength components can be produced, but it requires extensive time and large molds
Solution Approach 1:
The invention changes the manufacturing parameters by selecting different processes for different block materials based on their specific strength requirements. High-strength blocks can be produced by forging or forged-casting hybrid methods, while other blocks use casting or steel plate processing. This parameter optimization maintains the required strength properties while significantly improving manufacturing speed and reducing mold requirements.
Solution Approach 2:
The casing becomes a composite structure made from block materials produced by different manufacturing methods, each optimized for its specific functional requirements. This allows high-strength sections to be produced with appropriate processes while other sections use faster manufacturing methods, achieving overall strength requirements with improved productivity.
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 significantly shortens the manufacturing time for casings by eliminating the need for a single large mold and allowing for efficient production of complex shapes without molds, reducing costs and labor, while ensuring high-strength components can withstand high pressures and temperatures.
Implementation Method 1
a step of forming the casing by welding the plurality of metal members to each other
Data Source
AI summary
A manufacturing method of a casing, the manufacturing method includes a step of manufacturing a plurality of metal members which are components constituting the casing including a casing body having a tubular shape that extends with an axis as a center; a step of arranging the plurality of metal members according to the casing to be formed; and a step of forming the casing by welding the plurality of metal members to each other, in which in the step of manufacturing the metal members, the plurality of metal members are manufactured by at least two kinds of manufacturing methods among forging, steel plate processing, casting, and a fused metal deposition method.