航空发动机机匣包容性机理及数值仿真方法研究
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摘要
航空发动机机匣包容问题非常复杂,涉及大变形、材料粘塑性和失效,以及极短时间内发动机各部件之间大量整体和局部高速高能相互作用,包含多种非线性特性。本文结合打靶试验、模拟机匣/叶片包容试验和真实风扇和涡轮机匣/叶片包容试验,采用理论分析和数值仿真相结合的方法,对以下问题进行了研究：
(1)进行了平板和机匣受圆柱弹和叶片弹撞击的对比研究。通过打靶试验,使用理论方法对靶板抗击穿性能和弹体侵彻能力进行了研究,对靶板吸能模式进行了分类,并给出了相应的能量计算公式。为计算叶片弹撞击情况下靶板凹陷变形能,提出了基于任意截面形状弹体撞击靶板的凹陷能量计算方法和公式。同时,理论分析了叶片弹体头部破碎和靶板失效模式转变机制,数值仿真研究了偏航角对叶片弹撞击靶板的影响。
(2)建立了航空发动机机匣/叶片包容性数值仿真方法。以高速旋转试验台上进行的一次模拟机匣/叶片包容试验为研究对象,采用ANSYS/LS-DYNA程序,评估了网格尺寸、接触刚度罚因子和摩擦系数对数值仿真结果的影响。研究结果表明,这些因素影响叶片与机匣之间的相互作用力、能量的转换和转化、机匣和叶片的变形及失效等。基于此,建立了适用于金属材料机匣/叶片包容性问题的数值仿真方法,并使用其它次包容试验对此方法进行了验证。
(3)深入研究了风扇机匣/叶片包容机理。使用建立的数值仿真方法对真实风扇机匣/叶片包容性进行了数值仿真计算,随后进行了真实风扇机匣/叶片包容试验,通过比较数值仿真与试验结果,验证了数值仿真结果的合理性和数值仿真方法的适用性。采用验证后的数值仿真模型,对风扇机匣/叶片包容机理进行了详细的分析,研究了叶片之间相互作用和转速对包容过程的影响。
(4)深入研究了涡轮机匣/叶片包容机理。与风扇机匣/叶片包容机理研究方法类似,通过涡轮机匣/叶片包容试验验证了数值仿真结果的正确性和数值仿真方法的合理性,使用数值仿真对涡轮机匣/叶片包容机理进行了详细的研究。结果表明,涡轮机匣/叶片包容机理与风扇机匣/叶片相比存在较大差异,叶片之间相互作用和转速对包容过程的影响也明显不同。
The containment process of failed rotor blades is very complex, which involves high-energy, high-speed interactions of numerous locally and remotely located engine components. It includes every nonlinear aspect of structural dynamics, such as large displacements, plastic behavior of the materials, and contact interaction between structural elements. It is of great importance to systematically and deeply study the containment of failed rotor blades for the improvement in both safety and design of aeroengine. To this end, the main researches are as follows:
(1) A comparative study involving aeroengine fan casing and plate target impacted by blade-like and cylindrical projectiles has been conducted. Based on the ballist impact tests carried out on the compressed gas gun, theoretical method has been used to analyze the perforation resistance of the target and the penetration capability of the projectile. For this purpose, the energy absorption modes of the target are classified and each mode is established with a corresponding theoretical model, among which, a new dishing energy calculation approach for an arbitrary cross-section projectile impact is proposed. The cause why the blade-like projectile nose shatters and the transformation mechanism of the failure mode on the target are also analyzed using theoretical methods. Moreover, the effects of yaw angle on the perforation process by the blade-like projectile have been investigated using numerical simulations.
(2) Simulation methodology for aeroengine failed blade containment analysis has been developed. One test selected from nine blade/case containment tests conducted on the high speed spin test facility is simulated with different finite element models using the com-mercially available explicit dynamic analysis code ANSYS/LS-DYNA to assess the effects of mesh size, contact penalty factor and friction coefficient on numerical simulations, wherein a numerical method for metal blade/case containment simulation is formed and developed. Then, the developed simulation method is applied to the other eight tests and good agreements are in general obtained between the numerical and the test results.
(3) The mechamism of the containment of failed fan blade has been investigated in detail. Firstly, numerical simulations for the containment analysis are conducted using the proposed simulation method, then, containment tests are carried out to validate the numerical results and the application of the proposed simulation method to real aeroengine fan blade containment analysis. Based on the validated FEM model, the mechamism of the containment of failed aeoegine fan blade is studied deeply and in detail.
(4) The containment of aeroengine turbine blade has been studied systematically. Similar to the research method for the containment of the fan blade, numerical simulations are validated through containment tests. It reveals that the applicability of the proposed simulation method to real aeroengine turbine blade containment analysis. Using numerical method, the containment of aeroengine turbine blade is studied systematically. It is found that the differences of the containment mechanism between the turbine and the fan components are large. Multi-blade effects and the influences of the released speed on the containment capability of the turbine casing depend on the impact angle and the impact location on the casing.
(1)进行了平板和机匣受圆柱弹和叶片弹撞击的对比研究。通过打靶试验,使用理论方法对靶板抗击穿性能和弹体侵彻能力进行了研究,对靶板吸能模式进行了分类,并给出了相应的能量计算公式。为计算叶片弹撞击情况下靶板凹陷变形能,提出了基于任意截面形状弹体撞击靶板的凹陷能量计算方法和公式。同时,理论分析了叶片弹体头部破碎和靶板失效模式转变机制,数值仿真研究了偏航角对叶片弹撞击靶板的影响。
(2)建立了航空发动机机匣/叶片包容性数值仿真方法。以高速旋转试验台上进行的一次模拟机匣/叶片包容试验为研究对象,采用ANSYS/LS-DYNA程序,评估了网格尺寸、接触刚度罚因子和摩擦系数对数值仿真结果的影响。研究结果表明,这些因素影响叶片与机匣之间的相互作用力、能量的转换和转化、机匣和叶片的变形及失效等。基于此,建立了适用于金属材料机匣/叶片包容性问题的数值仿真方法,并使用其它次包容试验对此方法进行了验证。
(3)深入研究了风扇机匣/叶片包容机理。使用建立的数值仿真方法对真实风扇机匣/叶片包容性进行了数值仿真计算,随后进行了真实风扇机匣/叶片包容试验,通过比较数值仿真与试验结果,验证了数值仿真结果的合理性和数值仿真方法的适用性。采用验证后的数值仿真模型,对风扇机匣/叶片包容机理进行了详细的分析,研究了叶片之间相互作用和转速对包容过程的影响。
(4)深入研究了涡轮机匣/叶片包容机理。与风扇机匣/叶片包容机理研究方法类似,通过涡轮机匣/叶片包容试验验证了数值仿真结果的正确性和数值仿真方法的合理性,使用数值仿真对涡轮机匣/叶片包容机理进行了详细的研究。结果表明,涡轮机匣/叶片包容机理与风扇机匣/叶片相比存在较大差异,叶片之间相互作用和转速对包容过程的影响也明显不同。
The containment process of failed rotor blades is very complex, which involves high-energy, high-speed interactions of numerous locally and remotely located engine components. It includes every nonlinear aspect of structural dynamics, such as large displacements, plastic behavior of the materials, and contact interaction between structural elements. It is of great importance to systematically and deeply study the containment of failed rotor blades for the improvement in both safety and design of aeroengine. To this end, the main researches are as follows:
(1) A comparative study involving aeroengine fan casing and plate target impacted by blade-like and cylindrical projectiles has been conducted. Based on the ballist impact tests carried out on the compressed gas gun, theoretical method has been used to analyze the perforation resistance of the target and the penetration capability of the projectile. For this purpose, the energy absorption modes of the target are classified and each mode is established with a corresponding theoretical model, among which, a new dishing energy calculation approach for an arbitrary cross-section projectile impact is proposed. The cause why the blade-like projectile nose shatters and the transformation mechanism of the failure mode on the target are also analyzed using theoretical methods. Moreover, the effects of yaw angle on the perforation process by the blade-like projectile have been investigated using numerical simulations.
(2) Simulation methodology for aeroengine failed blade containment analysis has been developed. One test selected from nine blade/case containment tests conducted on the high speed spin test facility is simulated with different finite element models using the com-mercially available explicit dynamic analysis code ANSYS/LS-DYNA to assess the effects of mesh size, contact penalty factor and friction coefficient on numerical simulations, wherein a numerical method for metal blade/case containment simulation is formed and developed. Then, the developed simulation method is applied to the other eight tests and good agreements are in general obtained between the numerical and the test results.
(3) The mechamism of the containment of failed fan blade has been investigated in detail. Firstly, numerical simulations for the containment analysis are conducted using the proposed simulation method, then, containment tests are carried out to validate the numerical results and the application of the proposed simulation method to real aeroengine fan blade containment analysis. Based on the validated FEM model, the mechamism of the containment of failed aeoegine fan blade is studied deeply and in detail.
(4) The containment of aeroengine turbine blade has been studied systematically. Similar to the research method for the containment of the fan blade, numerical simulations are validated through containment tests. It reveals that the applicability of the proposed simulation method to real aeroengine turbine blade containment analysis. Using numerical method, the containment of aeroengine turbine blade is studied systematically. It is found that the differences of the containment mechanism between the turbine and the fan components are large. Multi-blade effects and the influences of the released speed on the containment capability of the turbine casing depend on the impact angle and the impact location on the casing.
引文
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