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Method of manufacturing rotor such as impeller or turbine wheel

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20140034262 patent thumbnailZoom

Method of manufacturing rotor such as impeller or turbine wheel


Disclosed is a method of manufacturing an impeller or a turbine wheel having a disk hub and an air foil. The method includes forming a mold for casting including a cavity of a shape corresponding to the rotor, arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting, injecting molten metal into the mold for casting where the core has been arranged, and removing the core from a casting which has been cast in the mold for casting.
Related Terms: G Rotor

Browse recent Samsung Techwin Co., Ltd. patents - Changwon-city, KR
USPTO Applicaton #: #20140034262 - Class: 164 24 (USPTO) -
Metal Founding > Process >Shaping A Forming Surface (e.g., Mold Making, Etc.) >Shaping Fluent Material To Form Mold >Composite, Plural Part Or Multilayered Mold >Sequentially Forming Mold Portions On Same Shaping Member

Inventors: Jeong-seung Lee

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The Patent Description & Claims data below is from USPTO Patent Application 20140034262, Method of manufacturing rotor such as impeller or turbine wheel.

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CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority from Korean Patent Application No. 10-2012-0084990, filed on Aug. 2, 2012, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND

1. Field

Methods consistent with exemplary embodiments relate to manufacturing a rotor such as an impeller or a turbine wheel, and more particularly, to manufacturing an impeller or a turbine wheel that may be used to various machines such as a compressor and a turbine.

2. Description of the Related Art

A rotor such as an impeller or a turbine wheel is used for a machine, such as a compressor and a turbine.

FIG. 1A schematically illustrates a cross-sectional shape of an impeller or a turbine wheel 1 of a compressor. Referring to FIG. 1A, the impeller or the turbine wheel 1 includes a disk hub 12 and a plurality of wings (air foil 14) that are arranged along the outer circumference of the disk hub 12. A fillet 18 is formed at a portion where the disk hub 12 is connected to the air foil 14. A penetration hole 11 is processed for combination with a shaft (not shown) in the integrally manufactured impeller or turbine wheel 1.

The impeller or turbine wheel 1 is a part that is rapidly rotated which generates a very large centrifugal load during operation, thereby also generating a high stress state due to the centrifugal load. In order to ensure an appropriate lifespan and structural stability in such an operation environment, the impeller or turbine wheel 1 should use materials of a high strength. However, there is a limit in selecting materials of the impeller or turbine wheel 1.

Furthermore, there is a large difference in a volume between the air foil 14 and the disk hub 12 when precisely casting. Thus, the thin air foil part is first solidified in molten metal, and the disk hub of a large volume is solidified later. Since, however, contraction occurs as the disk hub is solidified, tensile stress occurs within the disk hub.

FIG. 1B schematically illustrates a casting process of the impeller or the turbine wheel 1. As illustrated in FIG. 1B, in the molten metal injected into a mold 20, as solidification progresses in a direction from the air foil 14 to a central part 15 of the disk hub 12, the disk hub 12 contracts and tensile stress occurs. In some cases, a cavity may be formed within the disk hub 12.

Such tensile stress may generate remaining stress at the fillet 18, which is a connection part between the air foil 14 and the disk hub 12, or may cause a defect such as a hot tear or a crack. Furthermore, the shape of the air foil 14 may be distorted or the outer shape of the disk hub 12 may be changed by internal stress generated when the disk hub 12 is solidified.

The problem at the time of precision casting worsens as the size of the impeller or the turbine wheel increases. Since, however, casting materials usually have a low mechanical strength, the casting method may not be suitable for manufacturing a large-scale impeller or turbine. Hence, in the case of a large impeller or turbine wheel, a manufacturing method that mechanically processes an expensive forged bar should be used, which significantly increases manufacturing costs.

SUMMARY

One or more exemplary embodiments provide a method of manufacturing a rotor such as an impeller or a turbine wheel for effectively restricting casting defects such as a hot crack and a dimensional defect that may be generated during a precision casting process.

According to an aspect of an exemplary embodiment, there is provided a method of manufacturing a rotor, the method including: forming a mold for casting including a cavity of a shape corresponding to the rotor; arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting; injecting molten metal into the mold for casting where the core has been arranged; and removing the core from a casting which has been cast in the mold for casting.

The forming the mold for casting may include slurry-coating a wax model of the shape corresponding to the rotor, and the core may have been injected into the wax model in advance when arranging the core in the cavity of the mold for casting.

The method may further include: preparing a mold for wax having a cavity of the shape corresponding to the rotor; arranging the core in an inside of the cavity of the mold for wax; injecting wax into the inside of the cavity of the mold for wax where the core has been arranged, and solidifying the wax; and extracting the wax model solidified in the mold for wax so that the core is injected into the wax model in advance.

The core may be arranged to revolve around a rotation axis of the rotor in the inside of the rotor.

The core may include ceramic, and the core may be removed by a ceramic leaching process when removing the core from the casting.

The removing the mold for casting and the removing the core from the casing may be performed simultaneously.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects will become more apparent by describing in detail exemplary embodiments with reference to the attached drawings, in which:

FIG. 1A a diagram schematically illustrating a cross-section of a related art impeller or turbine wheel;

FIG. 1B is a diagram schematically illustrating a part of a casting process of the related art impeller or turbine wheel;



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Industry Class:
Metal founding
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stats Patent Info
Application #
US 20140034262 A1
Publish Date
02/06/2014
Document #
13954395
File Date
07/30/2013
USPTO Class
164 24
Other USPTO Classes
164/6
International Class
22D25/02
Drawings
8


G Rotor


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