镍基高温合金整体叶轮高效加工应用基础研究
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摘要
整体叶轮作为发动机透平机械核心部件，工作温度高，承受交变、冲击载荷，苛刻的工作条件对整体叶轮材料性能提出高要求。镍基高温合金在高温下具有良好的抗氧化、抗腐蚀、抗蠕变性能以及优异的疲劳寿命，适合作为整体叶轮材料。然而，良好的物理、机械性能意味着较差的切削加工性能，镍基高温合金切削过程中切削力大、切削温度高、刀具磨损快、加工硬化与残余应力显著，给切削刀具与切削参数的选择带来极大挑战。除了材料难加工之外，由于发动机大推升比与高效率的要求，整体叶轮结构趋于复杂化，本文所研究的整体叶轮属于半开式–长短叶片离心整体叶轮。这一类整体叶轮流道窄而深、开敞性差，叶片薄、曲面扭曲大，叶片长厚比大，易发生切削变形和振动，对切削过程稳定性要求高。
镍基高温合金切削过程中随着切削速度增大会先后出现切屑自由表面的周期性裂纹扩展与剪切带局部热塑性失稳而生成锯齿形切屑。低速时切屑自由表面材料的应变硬化效应远超过剪切带内部材料的热软化效应，从而切屑自由表面材料脆性增大，切屑在弯曲过程中容易产生微裂纹；高速时剪切带内部材料的热软化效应远远大于切屑自由表面的应变硬化效应，从而出现局部热塑性失稳，材料沿剪切面滑移而形成锯齿形切屑。锯齿生成过程中切削力产生周期性锯齿类波动，使得切削刃承受周期性冲击载荷，易加剧切削刀具磨损。
开展叶片侧铣力学建模与表面完整性研究。建立变切削厚度的三维力–热耦合的微单元有限元模型，对参与切削的微元切削力积分得到仿真切削力，进而获得切削力导致的叶片变形。建立连续进刀的变切削厚度的力–热耦合等效二维铣削残余应力模型，获得残余应力释放导致的叶片变形，研究切削刃钝圆半径对残余应力再分布的影响规律。针对叶片半精铣削工艺特征，开展加工硬化试验研究。通过对不同切削参数的切削力、残余应力与加工硬化及对叶片半精侧铣影响的试验或仿真研究，获得优化切削参数。
针对叶轮流道插铣过程刀具弱刚性特点，建立大圆角插铣刀非对称插铣切削力模型与切削动力学方程，结合插铣模态试验获得基于振动微位移与“让刀”位移的插铣切削力，对插铣切削参数进行优化。针对精加工侧铣叶片刚性差且刚度变化特点，建立了基于再生切削颤振的稳定性模型，获得临界切深与机床转速的稳定性方程，结合模态试验得到不同厚度叶片的模态参数，获得叶片刚度动态变化下的稳定性条件。
在本文基础理论与试验研究基础上，形成镍基高温合金整体叶轮成套工艺技术，成功应用于国家863项目某航空公司某型号航空整体叶轮单件试制，并成功投入台架试验。
As the key component of turbine machinery of aero-engine, integrated impellerhas an extremely severe working environment with high temperature and alternatingshock load, which requires the high performance of impeller materials. Nickel basedsuperalloy is considered as a suitable materials for integrated impeller for its goodoxidation resistance as well as corrosion resistance and creep resistance and excellentfatigue life at high temperature. However, good physical and mechanical propertyoften means poor machinability. Especially, great challenge is encountered inmachining of nickel based superalloy because of big cutting force, high cuttingtemperature, severe tool wear as well as notable machining hardening and residualstresses. Except for difficult-to-cut material, the structure of integrated impeller ismore complicate than before due to the requirement of big thrust-weight ratio andhigh efficiency of aero-engine. This research focuses on the semi-open centrifugalnickel-based superalloy (GH4169) impeller with long-short blade. This kind ofimpeller often has narrow flow passage, thin and twist blade. Machining of this kindof impeller becomes very difficult for cutting deformation and cutting vibration wouldbe often happened, which requires high stability for machining process.
Saw tooth chip formation due to the local thermal-plastic instability in the shearzone and the periodically brittle break in the chip free surface appears in the millingprocess of GH4169when the cutting speed increases. It is because the strainhardening effect in the chip free surface far exceeds the thermal softening effect in theshear zone under low cutting speed. Thus material brittleness near the chip freesurface increases and micro-crack propagation happens. In contrast, the thermalsoftening effect in the shear zone far exceeds the strain hardening effect in the chip free surface under high cutting speed. Then the local thermal-plastic instability causesmaterials sliding along the shear surface and saw tooth chip formation. Furthermore, itis also found that the cutting force fluctuates at almost the same frequency of thesaw-tooth, which makes the cutting tool enduring periodic shock load and fast wear.
A three-dimensional thermal-mechanical finite element model based on variableundeformed chip is established to predict cutting force. Then the deformation of bladeduring milling process could be obtained. An effective two-dimensional finite elementmodel considering the continuous feed effect is established to predict residual stressand the effect of cutting edge radius on residual stress is also evaluated, and then thedeformation of blade after milling process could be obtained. An experiment is carriedout to validate the finite element model and study the working hardening underdifferent cutting conditions. At last, optimal parameters could be obtained.
Because of the weak rigid of plunge milling tool, the cutting force model as wellas the kinetic equation is established for the plunge milling tool with big corner radius.With the help of modal test, cutting force based on tool chatter displacement anddeformation could be obtained so the stable cutting condition could be determined. Aresearch on stability of the dynamic weak rigid blade flank milling is also carried out.A stability model based on regeneration chatter is established to obtain therelationship between critical dept of cut and spindle speed. A modal test is carried outto acquire modal parameter at different blade thickness. At last, stable cuttingconditions could be obtained for flank milling of the dynamic weak rigid blade.
Based on the fundamental theory and experiment researches, a complete set ofmachining process for nickel based superalloy has been successfully applied in themanufacturing process of a certain type of integrated impeller, which comes from anational “863” High-Tech Program. The integrated impeller has been applied in benchtest.
镍基高温合金切削过程中随着切削速度增大会先后出现切屑自由表面的周期性裂纹扩展与剪切带局部热塑性失稳而生成锯齿形切屑。低速时切屑自由表面材料的应变硬化效应远超过剪切带内部材料的热软化效应，从而切屑自由表面材料脆性增大，切屑在弯曲过程中容易产生微裂纹；高速时剪切带内部材料的热软化效应远远大于切屑自由表面的应变硬化效应，从而出现局部热塑性失稳，材料沿剪切面滑移而形成锯齿形切屑。锯齿生成过程中切削力产生周期性锯齿类波动，使得切削刃承受周期性冲击载荷，易加剧切削刀具磨损。
开展叶片侧铣力学建模与表面完整性研究。建立变切削厚度的三维力–热耦合的微单元有限元模型，对参与切削的微元切削力积分得到仿真切削力，进而获得切削力导致的叶片变形。建立连续进刀的变切削厚度的力–热耦合等效二维铣削残余应力模型，获得残余应力释放导致的叶片变形，研究切削刃钝圆半径对残余应力再分布的影响规律。针对叶片半精铣削工艺特征，开展加工硬化试验研究。通过对不同切削参数的切削力、残余应力与加工硬化及对叶片半精侧铣影响的试验或仿真研究，获得优化切削参数。
针对叶轮流道插铣过程刀具弱刚性特点，建立大圆角插铣刀非对称插铣切削力模型与切削动力学方程，结合插铣模态试验获得基于振动微位移与“让刀”位移的插铣切削力，对插铣切削参数进行优化。针对精加工侧铣叶片刚性差且刚度变化特点，建立了基于再生切削颤振的稳定性模型，获得临界切深与机床转速的稳定性方程，结合模态试验得到不同厚度叶片的模态参数，获得叶片刚度动态变化下的稳定性条件。
在本文基础理论与试验研究基础上，形成镍基高温合金整体叶轮成套工艺技术，成功应用于国家863项目某航空公司某型号航空整体叶轮单件试制，并成功投入台架试验。
As the key component of turbine machinery of aero-engine, integrated impellerhas an extremely severe working environment with high temperature and alternatingshock load, which requires the high performance of impeller materials. Nickel basedsuperalloy is considered as a suitable materials for integrated impeller for its goodoxidation resistance as well as corrosion resistance and creep resistance and excellentfatigue life at high temperature. However, good physical and mechanical propertyoften means poor machinability. Especially, great challenge is encountered inmachining of nickel based superalloy because of big cutting force, high cuttingtemperature, severe tool wear as well as notable machining hardening and residualstresses. Except for difficult-to-cut material, the structure of integrated impeller ismore complicate than before due to the requirement of big thrust-weight ratio andhigh efficiency of aero-engine. This research focuses on the semi-open centrifugalnickel-based superalloy (GH4169) impeller with long-short blade. This kind ofimpeller often has narrow flow passage, thin and twist blade. Machining of this kindof impeller becomes very difficult for cutting deformation and cutting vibration wouldbe often happened, which requires high stability for machining process.
Saw tooth chip formation due to the local thermal-plastic instability in the shearzone and the periodically brittle break in the chip free surface appears in the millingprocess of GH4169when the cutting speed increases. It is because the strainhardening effect in the chip free surface far exceeds the thermal softening effect in theshear zone under low cutting speed. Thus material brittleness near the chip freesurface increases and micro-crack propagation happens. In contrast, the thermalsoftening effect in the shear zone far exceeds the strain hardening effect in the chip free surface under high cutting speed. Then the local thermal-plastic instability causesmaterials sliding along the shear surface and saw tooth chip formation. Furthermore, itis also found that the cutting force fluctuates at almost the same frequency of thesaw-tooth, which makes the cutting tool enduring periodic shock load and fast wear.
A three-dimensional thermal-mechanical finite element model based on variableundeformed chip is established to predict cutting force. Then the deformation of bladeduring milling process could be obtained. An effective two-dimensional finite elementmodel considering the continuous feed effect is established to predict residual stressand the effect of cutting edge radius on residual stress is also evaluated, and then thedeformation of blade after milling process could be obtained. An experiment is carriedout to validate the finite element model and study the working hardening underdifferent cutting conditions. At last, optimal parameters could be obtained.
Because of the weak rigid of plunge milling tool, the cutting force model as wellas the kinetic equation is established for the plunge milling tool with big corner radius.With the help of modal test, cutting force based on tool chatter displacement anddeformation could be obtained so the stable cutting condition could be determined. Aresearch on stability of the dynamic weak rigid blade flank milling is also carried out.A stability model based on regeneration chatter is established to obtain therelationship between critical dept of cut and spindle speed. A modal test is carried outto acquire modal parameter at different blade thickness. At last, stable cuttingconditions could be obtained for flank milling of the dynamic weak rigid blade.
Based on the fundamental theory and experiment researches, a complete set ofmachining process for nickel based superalloy has been successfully applied in themanufacturing process of a certain type of integrated impeller, which comes from anational “863” High-Tech Program. The integrated impeller has been applied in benchtest.
引文
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