Geometric parameter-based optimization of the die profile for the investment casting of aerofoil-shaped turbine blades

Dimensional accuracy is one of the most important criteria in the investment casting of turbine blades for aero engine applications. Although investment casting is an ideal route for producing net-shaped components, it necessitates accurate determination of the casting die profile. To avoid extensive modifications on the die cavity shape, this study proposes a simple but efficient inverse design method that adjusts certain geometric parameters to establish the die profile. Parameterized modeling is achieved by identifying the geometric parameters that describe the mean camber line of the blade profile. Meanwhile, blade shrinkages at different positions are effectively remedied through the adjustment of the parameters using the inverse iteration algorithm proposed in this paper. The relative positions among the cross-sections can also be varied to rectify the twist deformation of the blade, thereby guaranteeing the dimensional accuracy of the turbine blades. The applicability of this method is validated using numerical simulation data and experimental results.