离心压缩机受损叶轮再制造方法
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摘要
叶轮是离心压缩机的核心功能部件,极易出现损坏。受损叶轮再制造技术国内面临的主要问题是缺少设计数据。为此,提出一种基于受损叶轮结构特征建立再制造目标模型的方法。设计了离心压缩机受损叶轮的再制造流程;对受损叶轮原始三维点云进行滤波和精简;针对叶轮叶片的损伤区域和未损伤区域,分别提取并拟合叶片截面的边界曲线;重建叶轮叶片的再制造目标模型,通过布尔运算得到叶片损伤部位的三维模型。以离心压缩机受损叶轮为例,进行了再制造实验,再制造后的叶轮误差精度在±0.5 mm范围内,满足工作要求并已投入使用,证明了本方法的可行性。
Impeller is key functional unit of centrifugal compressor. It is widely used in industrial and agricultural fields and often subjects to damage because of the bad work environment. Since the technology of remanufacturing the impeller has been dominated by foreign companies,domestic companies have to invest a tremendous amount of cost and time in having damaged impeller repaired. This paper is to put forward a method in an attempt to remanufacture damaged impeller based on structure characteristics. Firstly,the process of remanufacturing the damaged impeller was designed. Secondly,the point cloud data of damaged impeller was acquired; the original point cloud data were filtered and simplified reasonably to improve modeling accuracy and efficiency. Thirdly,for the un-damaged area of the impeller blade,the SS,PS,LE and TE of the cross-section point cloud were automatically identified,the cross-section curve of the impeller blade was extracted and fitted based on design features; for the damaged area of the impeller blade,the boundary curve of the impeller blade cross-section was extracted and fitted using grey prediction method; the 3D digital models of impeller blade were reconstructed and the 3D model of damaged blade was obtained via Boolean operation. Finally,the 3D point cloud processplatform and reconstruction experiment platform were introduced; using laser cladding forming technology and adaptive grinding,an application example of remanufactured impeller was given,which proved that the method is feasible,and the future research direction was also proposed.
Impeller is key functional unit of centrifugal compressor. It is widely used in industrial and agricultural fields and often subjects to damage because of the bad work environment. Since the technology of remanufacturing the impeller has been dominated by foreign companies,domestic companies have to invest a tremendous amount of cost and time in having damaged impeller repaired. This paper is to put forward a method in an attempt to remanufacture damaged impeller based on structure characteristics. Firstly,the process of remanufacturing the damaged impeller was designed. Secondly,the point cloud data of damaged impeller was acquired; the original point cloud data were filtered and simplified reasonably to improve modeling accuracy and efficiency. Thirdly,for the un-damaged area of the impeller blade,the SS,PS,LE and TE of the cross-section point cloud were automatically identified,the cross-section curve of the impeller blade was extracted and fitted based on design features; for the damaged area of the impeller blade,the boundary curve of the impeller blade cross-section was extracted and fitted using grey prediction method; the 3D digital models of impeller blade were reconstructed and the 3D model of damaged blade was obtained via Boolean operation. Finally,the 3D point cloud processplatform and reconstruction experiment platform were introduced; using laser cladding forming technology and adaptive grinding,an application example of remanufactured impeller was given,which proved that the method is feasible,and the future research direction was also proposed.
引文
1舒林森,曹华军,许磊,等.离心压缩机再制造叶轮结构特征建模方法及应用[J].机械工程学报,2014,50(3):184-190.SHU L S,CAO H J,XU L,et al.3D characteristic modeling method and application for remanufactured impeller of centrifugal compressor[J].Journal of Mechanical Engineering,2014,50(3):184-190.(in Chinese)
2 MOHAGHEGH K,SADEGHI M H,ABDULLAH A.Reverse engineering of turbine blades based on design intent[J].International Journal Advanced Manufacturing Technology,2007,32(6):1009-1020.
3 MOHAGHEGH K,MOHAMMAD H,ABDULLAH A,et al.Improvement of reverse-engineered turbine blades using construction geometry[J].International Journal Advanced Manufacturing Technology,2010,49(7):675-678.
4 YILMAZ O,DOMINIC N,NABIL G,et al.A study of turbomachinery components machining and repairing methodologies[J].Aircraft Engineering and Aerospace Technology,2005,77(6):455-466.
5 YILMAZ O,GINDY N,GAO J.A repair and overhaul methodology for aeroengine components[J].Robotics and ComputerIntegrated Manufacturing,2010,26(2):190-201.
6 PIYA C,WILSON J M,MURUGAPPAN S.Virtual repair:geo-metric reconstruction for remanufacturing gas turbine blades[C]∥Proceedings of the ASME 2011 International Design Engineering Technical Conferences&Computers and Information in Engineering Conference,2011:1-10.
7 HUANG H,GONG Z M,CHEN X Q,et al.Smart robotic sys-tem for 3D profile turbine vane airfoil repair[J].International Journal of Advanced Manufacture Technology,2003,21(3):275-283.
8 周佩剑,王福军,姚志峰.旋转失速条件下离心泵叶轮压力脉动特性研究[J].农业机械学报,2015,46(10):56-61.ZHOU P J,WANG F J,YAO Z F.Investigation of pressure fluctuation in centrifugal pump impeller under rotating stall conditions[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(10):56-61.(in Chinese)
9 李伟,杨勇飞,施卫东,等.基于双向流固耦合的混流泵叶轮力学特性研究[J].农业机械学报,2015,46(12):82-88.LI W,YANG Y F,SHI W D,et al.Mechanical properties of mixed-flow pump impeller based on bidirectional fluid-structure interaction[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(12):82-88.(in Chinese)
10 董玲,杨洗陈,张海明,等.自由曲面破损零件激光再制造修复路径生成[J].中国激光,2012,39(7):1-6.DONG L,YANG X C,ZHANG H M,et al.Path generation for repairing damaged parts of freeform[J].Chinese Journal of Lasers,2012,39(7):1-6.(in Chinese)
11 董玲,杨洗陈,雷剑波,等.基于机器视觉的激光再制造机器人离线自动编程研究[J].中国激光,2012,40(10):1-8.DONG L,YANG X C,LEI J B,et al.Off-line automatic programming research of laser remanufacturing robot based on machine vision[J].Chinese Journal of Lasers,2012,40(10):1-8.(in Chinese)
12 符永宏,杨巍,张华伟,等.激光微造型凸轮副的摩擦磨损[J].农业机械学报,2010,41(1):216-219.FU Y H,YANG W,ZHANG H W,et al.Friction and wear of cam with laser micro-texture under lubrication[J].Transactions of the Chinese Society for Agricultural Machinery,2010,41(1):216-219.(in Chinese)
13 任乃飞,曹松.选择性激光烧结金属粉末材料的研究进展[J].农业机械学报,2005,36(8):147-153.REN N F,CAO S.Research advances of metallic powder materials by selective laser sintering[J].Transactions of the Chinese Society for Agricultural Machinery,2005,36(8):147-153.(in Chinese)
14 曹爽,岳建平,马文.基于特征选择的双边滤波点云去噪算法[J].东南大学报:自然科学版,2013,43(11):351-354.CAO S,YUE J P,MA W.Bilateral filtering de-noise algorithm for point cloud based on feature selection[J].Journal of Southeast University:Natural Science Edition,2013,43(11):351-354.(in Chinese)
15 李启东,李文龙,周莉萍.一种曲面特征保持的航空叶片点云精简方法[J].中国机械工程,2014,25(16):2204-2212.LI Q D,LI W L,ZHOU L P.A surface feature-preserving point cloud simplification method for aviation blades[J].China Mechanical Engineering,2014,25(16):2204-2212.(in Chinese)
16 赖喜德.叶片式流体机械的数字化设计与制造[M].成都:四川大学出版社,2007:109-115.
17 王浩,王立文,王涛,等.航空发动机损伤叶片再制造修复方法与实现[J].航空学报,2016,37(3):1036-1048.WANG H,WANG L W,WANG T,et al.Method and implementation of remanufacture and repair of aircraft engine blades[J].Aeronautica et Astronautica Sinica,2016,37(3):1036-1048.(in Chinese)
18 王涛,丁华鹏,刘一骝,等.基于叶型特征重建和缺陷模型提取的LDMD叶片再制造[J].农业机械学报,2015,46(8):333-337.WANG T,DING H P,LIU Y L,et al.LDMD-oriented blade remanufacturing based on CSC character reconstruction and defect model extraction[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(8):333-337.(in Chinese)
19 田庆国,葛宝臻,郁道银.基于灰色预测GM(1,1)模型的网格孔洞填补算法[J].工程图学学报,2007,28(3):78-83.TIAN Q G,GE B Z,YU D Y.Hole-filling algorithm in mesh surface based on grey model GM(1,1)[J].Journal of Engineering Graphics,2007,28(3):78-83.(in Chinese)
2 MOHAGHEGH K,SADEGHI M H,ABDULLAH A.Reverse engineering of turbine blades based on design intent[J].International Journal Advanced Manufacturing Technology,2007,32(6):1009-1020.
3 MOHAGHEGH K,MOHAMMAD H,ABDULLAH A,et al.Improvement of reverse-engineered turbine blades using construction geometry[J].International Journal Advanced Manufacturing Technology,2010,49(7):675-678.
4 YILMAZ O,DOMINIC N,NABIL G,et al.A study of turbomachinery components machining and repairing methodologies[J].Aircraft Engineering and Aerospace Technology,2005,77(6):455-466.
5 YILMAZ O,GINDY N,GAO J.A repair and overhaul methodology for aeroengine components[J].Robotics and ComputerIntegrated Manufacturing,2010,26(2):190-201.
6 PIYA C,WILSON J M,MURUGAPPAN S.Virtual repair:geo-metric reconstruction for remanufacturing gas turbine blades[C]∥Proceedings of the ASME 2011 International Design Engineering Technical Conferences&Computers and Information in Engineering Conference,2011:1-10.
7 HUANG H,GONG Z M,CHEN X Q,et al.Smart robotic sys-tem for 3D profile turbine vane airfoil repair[J].International Journal of Advanced Manufacture Technology,2003,21(3):275-283.
8 周佩剑,王福军,姚志峰.旋转失速条件下离心泵叶轮压力脉动特性研究[J].农业机械学报,2015,46(10):56-61.ZHOU P J,WANG F J,YAO Z F.Investigation of pressure fluctuation in centrifugal pump impeller under rotating stall conditions[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(10):56-61.(in Chinese)
9 李伟,杨勇飞,施卫东,等.基于双向流固耦合的混流泵叶轮力学特性研究[J].农业机械学报,2015,46(12):82-88.LI W,YANG Y F,SHI W D,et al.Mechanical properties of mixed-flow pump impeller based on bidirectional fluid-structure interaction[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(12):82-88.(in Chinese)
10 董玲,杨洗陈,张海明,等.自由曲面破损零件激光再制造修复路径生成[J].中国激光,2012,39(7):1-6.DONG L,YANG X C,ZHANG H M,et al.Path generation for repairing damaged parts of freeform[J].Chinese Journal of Lasers,2012,39(7):1-6.(in Chinese)
11 董玲,杨洗陈,雷剑波,等.基于机器视觉的激光再制造机器人离线自动编程研究[J].中国激光,2012,40(10):1-8.DONG L,YANG X C,LEI J B,et al.Off-line automatic programming research of laser remanufacturing robot based on machine vision[J].Chinese Journal of Lasers,2012,40(10):1-8.(in Chinese)
12 符永宏,杨巍,张华伟,等.激光微造型凸轮副的摩擦磨损[J].农业机械学报,2010,41(1):216-219.FU Y H,YANG W,ZHANG H W,et al.Friction and wear of cam with laser micro-texture under lubrication[J].Transactions of the Chinese Society for Agricultural Machinery,2010,41(1):216-219.(in Chinese)
13 任乃飞,曹松.选择性激光烧结金属粉末材料的研究进展[J].农业机械学报,2005,36(8):147-153.REN N F,CAO S.Research advances of metallic powder materials by selective laser sintering[J].Transactions of the Chinese Society for Agricultural Machinery,2005,36(8):147-153.(in Chinese)
14 曹爽,岳建平,马文.基于特征选择的双边滤波点云去噪算法[J].东南大学报:自然科学版,2013,43(11):351-354.CAO S,YUE J P,MA W.Bilateral filtering de-noise algorithm for point cloud based on feature selection[J].Journal of Southeast University:Natural Science Edition,2013,43(11):351-354.(in Chinese)
15 李启东,李文龙,周莉萍.一种曲面特征保持的航空叶片点云精简方法[J].中国机械工程,2014,25(16):2204-2212.LI Q D,LI W L,ZHOU L P.A surface feature-preserving point cloud simplification method for aviation blades[J].China Mechanical Engineering,2014,25(16):2204-2212.(in Chinese)
16 赖喜德.叶片式流体机械的数字化设计与制造[M].成都:四川大学出版社,2007:109-115.
17 王浩,王立文,王涛,等.航空发动机损伤叶片再制造修复方法与实现[J].航空学报,2016,37(3):1036-1048.WANG H,WANG L W,WANG T,et al.Method and implementation of remanufacture and repair of aircraft engine blades[J].Aeronautica et Astronautica Sinica,2016,37(3):1036-1048.(in Chinese)
18 王涛,丁华鹏,刘一骝,等.基于叶型特征重建和缺陷模型提取的LDMD叶片再制造[J].农业机械学报,2015,46(8):333-337.WANG T,DING H P,LIU Y L,et al.LDMD-oriented blade remanufacturing based on CSC character reconstruction and defect model extraction[J].Transactions of the Chinese Society for Agricultural Machinery,2015,46(8):333-337.(in Chinese)
19 田庆国,葛宝臻,郁道银.基于灰色预测GM(1,1)模型的网格孔洞填补算法[J].工程图学学报,2007,28(3):78-83.TIAN Q G,GE B Z,YU D Y.Hole-filling algorithm in mesh surface based on grey model GM(1,1)[J].Journal of Engineering Graphics,2007,28(3):78-83.(in Chinese)