Rapid manufacturing technique used in the development of a regenerative pump impeller

Francis Quail, Matthew Stickland, Thomas Scanlon

Research output: Chapter in Book/Report/Conference proceedingChapter (peer-reviewed)

Abstract

This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, from the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 axis capability. With an impeller less than 75 mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts particularly in terms of surface finish will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump.
LanguageEnglish
Title of host publicationWorld congress on engineering 2009
EditorsS.I. Ao, L Gelman, D.W.L. Hukins, A. Hunter, A.M. Korsunsky
Place of PublicationChina
Pages1730-1736
Number of pages7
VolumeI & II
Publication statusPublished - 1 Jul 2009
EventWorld Congress on Engineering 2009 - London, , United Kingdom
Duration: 1 Jul 20093 Jul 2009

Publication series

NameLecture Notes in Engineering and Computer Science
PublisherInternational Association of Engineers, IAEng
Volume2176 & 2177
ISSN (Print)2078-0958
ISSN (Electronic)2078-0966

Conference

ConferenceWorld Congress on Engineering 2009
CountryUnited Kingdom
CityLondon,
Period1/07/093/07/09

Fingerprint

Pumps
Testing
Computational fluid dynamics
Photopolymers
Impellers
Rapid prototyping
Machining
Processing
Costs
Industry

Keywords

  • rapid manufacturing
  • rapid prototyping
  • rapid tooling

Cite this

Quail, F., Stickland, M., & Scanlon, T. (2009). Rapid manufacturing technique used in the development of a regenerative pump impeller. In S. I. Ao, L. Gelman, D. W. L. Hukins, A. Hunter, & A. M. Korsunsky (Eds.), World congress on engineering 2009 (Vol. I & II, pp. 1730-1736). (Lecture Notes in Engineering and Computer Science; Vol. 2176 & 2177). China.
Quail, Francis ; Stickland, Matthew ; Scanlon, Thomas. / Rapid manufacturing technique used in the development of a regenerative pump impeller. World congress on engineering 2009. editor / S.I. Ao ; L Gelman ; D.W.L. Hukins ; A. Hunter ; A.M. Korsunsky. Vol. I & II China, 2009. pp. 1730-1736 (Lecture Notes in Engineering and Computer Science).
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abstract = "This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, from the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 axis capability. With an impeller less than 75 mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts particularly in terms of surface finish will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump.",
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Quail, F, Stickland, M & Scanlon, T 2009, Rapid manufacturing technique used in the development of a regenerative pump impeller. in SI Ao, L Gelman, DWL Hukins, A Hunter & AM Korsunsky (eds), World congress on engineering 2009. vol. I & II, Lecture Notes in Engineering and Computer Science, vol. 2176 & 2177, China, pp. 1730-1736, World Congress on Engineering 2009, London, , United Kingdom, 1/07/09.

Rapid manufacturing technique used in the development of a regenerative pump impeller. / Quail, Francis; Stickland, Matthew; Scanlon, Thomas.

World congress on engineering 2009. ed. / S.I. Ao; L Gelman; D.W.L. Hukins; A. Hunter; A.M. Korsunsky. Vol. I & II China, 2009. p. 1730-1736 (Lecture Notes in Engineering and Computer Science; Vol. 2176 & 2177).

Research output: Chapter in Book/Report/Conference proceedingChapter (peer-reviewed)

TY - CHAP

T1 - Rapid manufacturing technique used in the development of a regenerative pump impeller

AU - Quail, Francis

AU - Stickland, Matthew

AU - Scanlon, Thomas

PY - 2009/7/1

Y1 - 2009/7/1

N2 - This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, from the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 axis capability. With an impeller less than 75 mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts particularly in terms of surface finish will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump.

AB - This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, from the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 axis capability. With an impeller less than 75 mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts particularly in terms of surface finish will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump.

KW - rapid manufacturing

KW - rapid prototyping

KW - rapid tooling

UR - http://www.iaeng.org/WCE2009/

M3 - Chapter (peer-reviewed)

SN - 978-988-17012-5-1

VL - I & II

T3 - Lecture Notes in Engineering and Computer Science

SP - 1730

EP - 1736

BT - World congress on engineering 2009

A2 - Ao, S.I.

A2 - Gelman, L

A2 - Hukins, D.W.L.

A2 - Hunter, A.

A2 - Korsunsky, A.M.

CY - China

ER -

Quail F, Stickland M, Scanlon T. Rapid manufacturing technique used in the development of a regenerative pump impeller. In Ao SI, Gelman L, Hukins DWL, Hunter A, Korsunsky AM, editors, World congress on engineering 2009. Vol. I & II. China. 2009. p. 1730-1736. (Lecture Notes in Engineering and Computer Science).