Abstract
The article is devoted to the exercising of a trial technological process for the manufacture of gas turbine engine (GTE) hot sections by the example of a solid-cast nozzle block. To do this, the authors made up a plan of the experiment associated with the search for optimal conditions and parameters of a technological process of the sector master mold layer-by-layer synthesis from a photopolymeric material. The paper tracks the interconnection between the parameters of a 3D printing system Objet Eden 350 and the materials in the growing process by the PolyJet technology and mechanical properties of a master mold in the context of their influence on the surface layer quality and geometric accuracy of the final GTE parts’ casting. Based upon the analysis of the obtained research results and taking into account technical requirements, the authors managed to grow a nozzle block sector master mold, get wax models and conduct an experimental casting of a solid cast nozzle block wheel.
Highlights
In the process of new high-tech products development and manufacture special attention is paid to the speed of research&development and testing&engineering work stages which, in its turn, significantly depends on the production facility technology capabilities
Pilot production is characterized by multi-variant research, frequent structure change and refining and, a continuous correction of technology tooling to manufacture a pilot batch, high-speed prototyping technologies become relevant, especially, in case of cast part manufacture
High-speed prototyping has shown good results in pilot production as it is adapted to the manufacture of complex configuration parts, such as, for example, gas turbine engine (GTE) blades [1]
Summary
In the process of new high-tech products development and manufacture special attention is paid to the speed of research&development and testing&engineering work stages which, in its turn, significantly depends on the production facility technology capabilities. The papers [3, 7, 8, 9] contain the results of the property analysis conducted for the samples manufacture with the help of the PolyJet technology after mechanical tests and roughness measurement. It should be mentioned that the considered papers do not contain the research on the volume shrinkage evaluation and change of the geometric parameters of the samples grown by means of the PolyJet technology. The availability of such results would provide for a more correct 3D design of part casting and assigning of an aggregate casting shrinkage. To determine the high-speed prototyping efficiency and the nature of manufacturing errors
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