汽轮机末级空心叶片热拉延成形研究
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摘要
针对传统的热压成形工艺不适合成形具有变截面复杂型线、大尺寸的空心叶片的问题,提出了一种适用于大尺寸、变截面复杂型线空心叶片的热拉延成形工艺.该工艺采用"上模-压边圈-下模"的结构形式,当叶片成形时压边圈与上模对加热的板料有力的作用,有效限制了叶片在成形过程中的自由流动,使材料得到较好变形,减少由于材料自由流动导致的回弹和扭曲.通过数值模拟分析了热拉延成形后叶片的成形质量和回弹量规律,确定了一组优化的成形工艺参数.根据得到的工艺参数进行了零件试制,通过回弹补偿最终得到满足产品质量要求、成形状态良好、尺寸精度较高的叶片背弧及内弧.
The traditional hot forming process is mainly used in the manufacture of hollow blade which has small size and simple profile,but it is not suitable for the hollow blade with large size and complex profile.So a hot stamping process of hollow blade with large size and complex profile was presented in this paper.The process adopted the structure form of upper die,blank holder and lower die.The blank holder and the upper die applied force on heating sheet to restrict free flow of material that would reduce strong distortion and springback during forming process.The forming quality of the blades and the rules of springback were studied by numerical simulation,and a group of optimal parameters was concluded.According to the optimal parameters,the parts trial was carried out and the springback compensation was applied.Finally,parts with good quality and high accuracy was manufactured through the new process.
The traditional hot forming process is mainly used in the manufacture of hollow blade which has small size and simple profile,but it is not suitable for the hollow blade with large size and complex profile.So a hot stamping process of hollow blade with large size and complex profile was presented in this paper.The process adopted the structure form of upper die,blank holder and lower die.The blank holder and the upper die applied force on heating sheet to restrict free flow of material that would reduce strong distortion and springback during forming process.The forming quality of the blades and the rules of springback were studied by numerical simulation,and a group of optimal parameters was concluded.According to the optimal parameters,the parts trial was carried out and the springback compensation was applied.Finally,parts with good quality and high accuracy was manufactured through the new process.
引文
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[2]Lu Z L,Fan Y X,Miao K,et al.Effects of adding aluminum oxide or zirconium oxide fibers on ceramic molds for casting hollow turbine blades[J].International Journal of Advanced Manufacturing Technology,2014,72(5-8):873-880.
[3]Jiang Ruisong,Wang Wenhu,Zhang Dinghua,et al.Wall thickness monitoring method for wax pattern of hollow turbine blade[J].International Journal of Advanced Manufacturing Technology,2016,83(5-8):949-960.
[4]王烜烽,苏化冰,滕树新,等.改善汽轮机空心静叶焊接自动化应用的研究[J].热力透平,2013,42(1):43-46.
[5]王烜烽,毛志刚,缪朗,等.汽轮机末级空心隔板静叶焊接变形试验与分析[J].热力透平,2014,43(2):127-130.
[6]Xun Y W,Tan M J.Applications of superplastic forming and diffusion bonding to hollow engine blades[J].Journal of Materials Processing Technology,2000,99(1-3):80-85.
[7]Zhao Bing,Li Zhiqiang,Hou Hongliang,et al.Three dimensional FEM simulation of titanium hollow blade forming process[J].Rare Metal Materials and Engineering,2010,39(6):963-968.
[8]吴心晨.宽弦空心风扇叶片超塑成形/扩散连接工艺研究[D].南京:南京航空航天大学机电学院,2015.
[9]周子钊,李新军,周应科,等.基于内高压成形方法的航空发动机空心叶片工艺设计[J].精密成形工程,2015,7(3):67-72.
[10]Lu Z L,Li D C,Tong Z Q,et al.Investigation into the direct laser forming process of steam turbine blade[J].Optics and Lasers in Engineering,2011,49(9-10):1101-1110.
[11]汤攀飞,王明娣,石世宏,等.一种新型汽轮机空心静叶片制造工艺的研究[J].应用激光,2014,34(5):442-445.
[12]熊建坤,陈达平,张春定.1000MW核电机组空心叶片国产化制造技术[J].东方汽轮机,2011(2):42-49.
[13]张春定,伍敏.变截面复杂型线空心静叶片成型工艺研究[J].东方汽轮机,2013(3):19-24.
[14]王发成,吕彦明,魏中兴,等.基于Dynaform的叶片冲压模拟与回弹补偿[J].轻工机械,2012,30(3):40-42.
[15]徐看,吕彦明,黄艳玲.基于Dynaform的空心叶片冲压回弹影响因素分析[J].热加工工艺,2014,43(7):138-141.