多目标约束的精锻叶片几何重构优化算法
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摘要
新型航空发动机已部分采用精密锻造工艺提高叶片的制造精度和效率。然而,精锻后的叶身型面与设计模型存在几何偏差,导致依据设计模型加工后的进/排气边与精锻的叶身型面不能很好地匹配。为了解决该问题,提出一种面向精锻叶片自适应加工的几何重构方法。首先,建立基于公差约束配准的目标函数,并采用粒子群优化(PSO)算法求解目标函数。其次,提出基于叶身变形趋势预测进/排气边轮廓的光顺重构算法。最后,通过精锻叶片自适应数控加工实验对提出的方案和算法进行验证。实验结果表明,该方案可以有效重构出合格的工艺模型,满足精锻叶片的精密数控加工要求。
The precision forging technology is the favored means to improve the machining accuracy and efficiency of aero-engine blade manufacturing.However,there is still a certain geometric deviation between the forged blade surface and the design model,causing the edges of the blade machined based on the design model cannot match well with the blade body.To solve this issue,ageometric reconstruction method for adaptive machining of the precision forged blade is proposed.The objective function of match is established based on the tolerance constraint,and the Particle Swarm Optimization(PSO)algorithm for solving this objective function is presented.A smoothing reconstruction algorithm is proposed to predict the profile of the edge shape based on deformation trend of the blade surface.Experiments verify effectiveness of the approach and algorithm proposed in this paper.The results show that this method can reconstruct a qualified model for high-efficiency and precision requirements of adaptive machining of the precision forged blade.This approach is finally verified with a precision forged blade by the adaptive CNC machining.
The precision forging technology is the favored means to improve the machining accuracy and efficiency of aero-engine blade manufacturing.However,there is still a certain geometric deviation between the forged blade surface and the design model,causing the edges of the blade machined based on the design model cannot match well with the blade body.To solve this issue,ageometric reconstruction method for adaptive machining of the precision forged blade is proposed.The objective function of match is established based on the tolerance constraint,and the Particle Swarm Optimization(PSO)algorithm for solving this objective function is presented.A smoothing reconstruction algorithm is proposed to predict the profile of the edge shape based on deformation trend of the blade surface.Experiments verify effectiveness of the approach and algorithm proposed in this paper.The results show that this method can reconstruct a qualified model for high-efficiency and precision requirements of adaptive machining of the precision forged blade.This approach is finally verified with a precision forged blade by the adaptive CNC machining.
引文
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[16]程云勇,王嫔,刘鹏军,等.基于误差控制的薄壁叶片椭圆弧形前后缘建模方法[J].计算机辅助设计与图形学学报,2016,28(1):155-161.CHENG Y Y,WANG P,LIU P J,et al.An error control based modeling method for ellipse leading edge and trailing edge reconstruction of thin-walled blade[J].Journal of Computer-Aided Design&Computer Graphics,2016,28(1):155-161(in Chinese).
[17]侯斐茹,万能,常智勇,等.轮廓度约束下近净成形叶片余量优化方法[J].航空学报,2017,38(7):299-308.HOU F R,WAN N,CHANG Z Y,et al.An allowance optimization method for near-net shape blade under profile tolerance constraints[J].Acta Aeronautica et Astronautica Sinica,2017,38(7):299-308(in Chinese).
[18]ZHANG Y,CHEN Z T,NING T.Reverse modeling strategy of aero-engine blade based on design intent[J].International Journal of Advanced Manufacturing Technology,2015,81(9-12):1781-1796.
[19]XU G,WANG G Z,CHEN W Y.Geometric construction of energy-minimizing Bézier curves[J].Science China Information Sciences,2011,54(7):1395-1406.
[20]施法中.计算机辅助几何设计与非均匀有理B样条[M].北京:高等教育出版社,2001.SHI F Z.Computer aided geometric design and non-uniform rational B-spline[M].Beijing:Higher Education Press,2001(in Chinese).
[21]PIEGL L,TILLER W.The NURBS book[M].2nd ed.New York:Springer-Verlag,1997.
[2]任军学,冯亚洲,米翔畅,等.航空发动机精锻叶片自适应数控加工技术[J].航空制造技术,2015,492(22):52-55.REN J X,FENG Y Z,MI X C,et al.Adaptive techniques in CNC machining of aeroengine precision forging blades[J].Aeronautical Manufacturing Technology,2015,492(22):52-55(in Chinese).
[3]MAKEM J E,OU H,ARMSTRONG C G.A virtual inspection framework for precision manufacturing of aerofoil components[J].Computer-Aided Design,2012,44(9):858-874.
[4]ZHANG D H,ZHANG Y,WU B H.Research on the adaptive machining technology of Blisk[J].Advanced Materials Research,2009,69-70:446-450.
[5]GAO J,CHEN X,YILMAZ O,et al.An integrated adaptive repair solution for complex aerospace components through geometry reconstruction[J].International Journal of Advanced Manufacturing Technology,2008,36(11-12):1170-1179.
[6]JAVIDRAD F,RAHMATI R.An integrated re-engineering plan for the manufacturing of aerospace components[J].Materials&Design,2009,30(5):1524-1532.
[7]MOHAGHEGH K,SADEGHI M H,ABDULLAH A.Reverse engineering of turbine blades based on design intent[J].International Journal of Advanced Manufacturing Technology,2007,32(9-10):1009-1020.
[8]MOHAGHEGH K,SADEGHI M H,ABDULLAH A,et al.Improvement of reverse-engineered turbine blades using construction geometry[J].International Journal of Advanced Manufacturing Technology,2010,49(5-8):675-687.
[9]DONG Y,ZHANG D,BU K,et al.Geometric parameter-based optimization of the die profile for the investment casting of aerofoil-shaped turbine blades[J].International Journal of Advanced Manufacturing Technology,2011,57(9-12):1245-1258.
[10]ZHAO Z,FU Y,LIU X,et al.Measurement-based geometric reconstruction for milling turbine blade using freeform deformation[J].Measurement,2017,101:19-27.
[11]LI Y,NI J.Constraints based nonrigid registration for 2D blade profile reconstruction in reverse engineering[J].Journal of Computing&Information Science in Engineering,2009,9(3):296-297.
[12]RONG Y,XU J,SUN Y.A surface reconstruction strategy based on deformable template for repairing damaged turbine blades[J].Proceedings of the Institution of Mechanical Engineers Part G:Journal of Aerospace Engineering,2014,228(12):2358-2370.
[13]LI L,LI C,TANG Y,et al.An integrated approach of reverse engineering aided remanufacturing process for worn components[J].Robotics and Computer Integrated Manufacturing,2017,48:39-50.
[14]蔺小军,陈悦,王志伟,等.面向自适应加工的精锻叶片前后缘模型重构[J].航空学报,2015,36(5):1695-1703.LIN X J,CHEN Y,WANG Z W,et al.Model restructuring about leading edge and tailing edge of precision forging blade for adaptive machining[J].Acta Aeronautica et Astronautica Sinica,2015,36(5):1695-1703(in Chinese).
[15]张艳,汪文虎,解晓娜,等.压气机辊轧叶片前后缘圆滑转接建模方法[J].计算机集成制造系统,2015,21(2):444-448.ZHANG Y,WANG W H,XIE X N,et al.Smooth connection modeling method between edge and body of compressor roll-forming blade[J].Computer Integrated Manufacturing Systems,2015,21(2):444-448(in Chinese).
[16]程云勇,王嫔,刘鹏军,等.基于误差控制的薄壁叶片椭圆弧形前后缘建模方法[J].计算机辅助设计与图形学学报,2016,28(1):155-161.CHENG Y Y,WANG P,LIU P J,et al.An error control based modeling method for ellipse leading edge and trailing edge reconstruction of thin-walled blade[J].Journal of Computer-Aided Design&Computer Graphics,2016,28(1):155-161(in Chinese).
[17]侯斐茹,万能,常智勇,等.轮廓度约束下近净成形叶片余量优化方法[J].航空学报,2017,38(7):299-308.HOU F R,WAN N,CHANG Z Y,et al.An allowance optimization method for near-net shape blade under profile tolerance constraints[J].Acta Aeronautica et Astronautica Sinica,2017,38(7):299-308(in Chinese).
[18]ZHANG Y,CHEN Z T,NING T.Reverse modeling strategy of aero-engine blade based on design intent[J].International Journal of Advanced Manufacturing Technology,2015,81(9-12):1781-1796.
[19]XU G,WANG G Z,CHEN W Y.Geometric construction of energy-minimizing Bézier curves[J].Science China Information Sciences,2011,54(7):1395-1406.
[20]施法中.计算机辅助几何设计与非均匀有理B样条[M].北京:高等教育出版社,2001.SHI F Z.Computer aided geometric design and non-uniform rational B-spline[M].Beijing:Higher Education Press,2001(in Chinese).
[21]PIEGL L,TILLER W.The NURBS book[M].2nd ed.New York:Springer-Verlag,1997.