基于3D打印技术的预研涡轮叶片精铸蜡型快速制造方法

针对航空预研涡轮叶片制造成本高、周期长等问题,提出一种基于光固化成型技术的涡轮叶片快速制造方法。根据涡轮叶片的结构特点设计蜡模模具及其冷却结构,采用光固化成型技术制造模具型壳和内植冷却流道,基于凝胶注模方法将氧化铝等陶瓷粉末填充于模具内腔,实现了涡轮叶片蜡模模具的快速制造;基于ANSYS模拟研究了蜡模模具和蜡模温度场分布;采用三坐标测量分析了涡轮叶片精度。研究结果表明:随形冷却流道明显改善了蜡模温度场的均匀性,缩短了蜡模的冷却时间,提高了蜡模的制造质量,金属涡轮叶片尺寸精度达到CT4~CT5等级,表面粗糙度Ra达到4.97μm,相对于金属模具制造方法,显著缩短了预研涡轮叶片的制造周期,大大降低了制造成本。

Rapid fabrication method of pre-research turbine blade wax precision mould based on 3D printing technology

Aimed at solving the high cost and long manufacturing cycle of aircraft pre-research turbine blades, a rapid fabricating method for turbine blade based on stereolithography is proposed. Wax mold and its cooling structure are designed with reference to the structure characteristic of the turbines blades. The shell and the inner cooling channels of the mold are prepared by stereolithography, and alumina powder is filled into the cavity of the mold by gel-casting, which can realize the fabrication of the wax mold of turbine blade. Temperature field distribution of the wax mold is simulated with ANSYS and turbine blade''s precision is investigated by using coordinate measuring machine. Result shows that the conformal cooling channels ameliorate the temperature field uniformity of the wax mold significantly, shorten the cooling time of the wax mold and improve the quality of the wax mold apparently. Accuracy of the wax mold reaches CT4-CT5 level with low surface roughness of R_a=4.97 μm, which shortens the pre-research cycle of metal turbine blades and reduces the manufacturing cost magnificently.