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Customer |
Turbine inlet housing
For an aircraft turbine, all necessary compressor stages for a test bench installation were made by rapid prototyping. Due to the fact that the guide vanes inside the compressor stages could not be machined afterwards, it was necessary to achieve the high accuracy demanded before this in the unfinished casting blank. The molds used for this are made by direct molding material milling in combination with Direct Croning® - batch parts and cores. Before the mold assembly, the individual mold segments were surveyed and the mold assembly itself supervised by a 3D measuring lever. The surface quality of Rz 6.3 necessary for aerodynamics was achieved by grinding after CNC machining.
This way, ACTech was able to achieve the customer's accuracy values, which were clearly below the usual sand casting tolerances.
It is possible to reach accuracy values which are, like these, well below the tolerances usual for sand casting by using a step-by-step optimisation of the mold assembly. In this procedure, both the individual mold segments and the complete mold are surveyed and compared with the result of the pouring. This way, the different shrinkage values in the various casting segments can be recognised and compensated when the next mold is produced.
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