摘要
钛合金宽弦空心风扇叶片是航空发动机的重要部件,具有复杂的结构特点,内部交替排列减重空腔与加强筋,采用基于复杂超塑性成形的传统多层工艺成形难度大。针对以上问题,提出一种基于热成形和扩散连接技术的新双层制造工艺,并且规划了一条毛坯优化设计的基本技术途径,更可靠可控的构建了内部加强筋。借用ABAQUS软件数值模拟成形,分析成形结果的厚度均匀性、结构完整性和表面缺陷,以及评估方法的实用性。以Ti-6Al-4V为成形材料,采用经尺寸优化后的最佳坯料,进行了一系列的实验来验证仿真结果。实验成功制造出无缺陷的缩比版钛合金宽弦空心风扇叶片,同时实验与仿真模拟结果非常吻合。
A new two-layer process based on hot forming and diffusion bonding for forming a hollow titanium wide-chord fan blade with complex geometries was developed. An essential approach for optimal blank design was proposed. The present process employed a more reliable and controllable method to construct the internal ribbons, instead of complicated superplastic forming. To evaluate the practicability, a numerical method was used to investigate the thickness uniformity, structural integrity and skin defects of forming results using ABAQUS. A series of experiments were conducted to validate the simulation results. The Ti-6 Al-4 V alloy was adopted as the forming material, and blanks optimized by the proposed approach were used. The results show that a scaled-down version of the hollow wide-chord fan blade without defects is successfully formed. In addition, it is observed that the experimentation and simulation agree well.
引文
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