Development of a hybrid technological scheme for manufacturing pattern equipment for pump impellers
DOI:
https://doi.org/10.15587/2706-5448.2026.357430Keywords:
model equipment, working wheels, CNC milling, additive technologies, digital controlAbstract
The research deals with the technological process of manufacturing pattern equipment for pump impellers with curved blades. Pattern equipment is a key element of foundry production, since it determines the geometry and quality of the future casting.
The paper addresses the problem of ensuring the dimensional accuracy and quality of pattern equipment for pump impellers. It is shown that three-axis CNC machining is limited in the manufacture of curved blades, whereas the use of five-axis machining centers involves significant costs and higher qualification requirements. Under these conditions, a transition to hybrid technological schemes becomes justified, combining three-axis CNC milling with additive 3D printing.
The research aimed to develop and substantiate a hybrid technological scheme for manufacturing pattern equipment. The scheme is based on a rational division of operations: base surfaces are produced by CNC milling, while complex-geometry elements, namely negative blade sections, are manufactured using 3D printing and digital inspection. The research employs CAD/CAM design, three-axis CNC machining, additive manufacturing, and measurement-based control methods. A comparative analysis of conventional and hybrid approaches was carried out. The hybrid technology ensures geometric deviations of the base surfaces within 0.1–0.3 mm, while additively manufactured blade elements achieve deviations within 0.1–0.15 mm. Due to the combination of CNC milling and 3D printing, the technological route is reduced by 30–40%, and the cost of pattern equipment decreases by 20–30% compared with five-axis machining.
The proposed scheme can be implemented at industrial enterprises equipped with three-axis CNC machines and additive manufacturing systems, without expensive five-axis machining centers.
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