某航空发动机叶片超塑成形/扩散连接工艺参数优化
摘要
航空发动机叶片是航空发动机重要部件之一,叶片是一个复杂的自由曲面零件,成形特别困难,叶片的设计和成形精度直接影响航空发动机的性能。传统航空发动机叶片的成形方法费时费力,精度还低。钛合金的叶片,由于材料的特性冷成形时回弹比较大、屈服强度也高,不易成形。但是利用超塑成形技术把材料加热到一定温度,材料进入超塑性后特别容易贴膜和成形,解决了加工困难的问题。这项技术的成形过程是非常复杂的一个过程,需要控制的参数多如:温度、摩擦系数,压力和时间的关系等。不同参数的组合对成形质量影响很大,厚度分布也不均匀,利用实验去验证浪费时间和财力,所以通过计算机利用有限元软件进行成形模拟优化参数、改善厚度分布有着十分重要的作用。
本文给出了宽弦空心风扇叶片的结构、材料、成形工艺,重点分析了超塑成形与扩散连接工艺的特点。本文根据超塑成形的工艺要求,利用有限元软件MSC.MARC对空心风扇叶片进行数值模拟分析。比较不同参数对成形和厚度分布的影响,优化参数得出优化P-T曲线。
本文对叶片试验件的厚度进行测量,验证有限元软件模拟的结果正确性,为以后研究提供依据。
The hollow fan blade is one of the most important parts in the aereoengine, the blade is a complex free-form surface part and form into the hollow fan blade is especially difficult. The design of the blades and the forming precision directly influence the aviation engine performance , the formation of the traditional aviation engine is time-consuming , and also the precision still low , but titanium alloys blade , due to the characteristics of the material is easier to springback when cold forming and the yield strength is also difficult to form, but by using the SPF technology and heating the material into a definite temperature , the material after the superplastic forming (SPF) is easy to patch ,which can solve the difficult problem in processing. The technology of forming process is very complex, so we need to analyze the parameters such as temperature, coefficient of friction, pressure with the time. The combination of different parameters on the forming quality is affected the thickness distribution that is not even, and it is also a waste of money and time to verify with the experiment, so using the MSC.MARC one the computer to form the simulation optimization parameters is a very important role to improve the thickness distribution.
This paper shows the structure, materials and SPD/DB of the hollow fan blades especially the characteristics of SPF/DB(Superplastic Forming/Diffusion Bonding) , the SPD/DB is accord to the design of the hollow fan blades and accuracy requirement , by using the element software MSC .MARC to analyze the numerical simulation analysis of the hollow fan blades, comparing different parameters on the forming and the influence of thickness distribution , the optimized parameters form the optimization P-T curve
A test of the blade thickness measurement also veries the correctness of the finite element software simulation results in the paper , which provides the basis for the future research .
本文给出了宽弦空心风扇叶片的结构、材料、成形工艺,重点分析了超塑成形与扩散连接工艺的特点。本文根据超塑成形的工艺要求,利用有限元软件MSC.MARC对空心风扇叶片进行数值模拟分析。比较不同参数对成形和厚度分布的影响,优化参数得出优化P-T曲线。
本文对叶片试验件的厚度进行测量,验证有限元软件模拟的结果正确性,为以后研究提供依据。
The hollow fan blade is one of the most important parts in the aereoengine, the blade is a complex free-form surface part and form into the hollow fan blade is especially difficult. The design of the blades and the forming precision directly influence the aviation engine performance , the formation of the traditional aviation engine is time-consuming , and also the precision still low , but titanium alloys blade , due to the characteristics of the material is easier to springback when cold forming and the yield strength is also difficult to form, but by using the SPF technology and heating the material into a definite temperature , the material after the superplastic forming (SPF) is easy to patch ,which can solve the difficult problem in processing. The technology of forming process is very complex, so we need to analyze the parameters such as temperature, coefficient of friction, pressure with the time. The combination of different parameters on the forming quality is affected the thickness distribution that is not even, and it is also a waste of money and time to verify with the experiment, so using the MSC.MARC one the computer to form the simulation optimization parameters is a very important role to improve the thickness distribution.
This paper shows the structure, materials and SPD/DB of the hollow fan blades especially the characteristics of SPF/DB(Superplastic Forming/Diffusion Bonding) , the SPD/DB is accord to the design of the hollow fan blades and accuracy requirement , by using the element software MSC .MARC to analyze the numerical simulation analysis of the hollow fan blades, comparing different parameters on the forming and the influence of thickness distribution , the optimized parameters form the optimization P-T curve
A test of the blade thickness measurement also veries the correctness of the finite element software simulation results in the paper , which provides the basis for the future research .
引文
[1]王乐安。国外航空发动机风扇叶片及其成形技术.航空科学技术,1995年,第1期
[2]朱林奇。国外超塑成形_扩散连接技术发展现状。航宇材料工艺,1996年,第2期
[3]楚武利刘前智胡春波。航空叶片机原理。西北工业大学出版社,2009年6月。
[4]林兆荣.金属超塑性成形原理及应用.北京:航空工业出版社,1990。
[5]文九巴等编著.超塑性应用技术.机械工业出版社.2005年。
[6]张德荣,超塑性力学,北京:航空工业出版社,1990.1.
[7]Barry Pridham,Adam Marriott,Brian Ginty.Process Simulation of Superplastic Forming of Titanium Structure.SAE 2001-01-2624
[8]郭和平曾元松韩秀全李志强。飞机钛合金整体结构的超塑成形焊接组合工艺技术。北京航空制造工程研究所。
[9]侯冠群,尚波生.宽弦空心风扇叶片技术的发展.航空制造工程,2002年,第12期
[10]Zhao Bing,Li Zhiqiang,Hou Hongliang,Liao Jinhua,Bai Bingzhe.Three Dimensional FEM Simulation of Titanium Hollow Blade Forming Process2010-07.
[11]J.R. Williamson. Aerospace Applications of SPF/DB. Superplastic Forming of Structural Alloys,TMS- AIME, Warrendale, PA, 1982, pp.291-306
[12]Y.W.Xun, M.J.Tan.Applications of superplastic forming and diffusion bonding to hollow engine blade. Journal of Materials Processing Technology 99, 2000, p.80-85
[13]Kajbyshev, O.A; Galimov, A.K; Kruglov, A.A; Lutfullin, R.Ya; Safiullin, R.V.Numerical analysis of the hollow fan blade designs.Problemy Mashinostraeniya I Nadezhnos'ti Mashin,n 1,2004,p.90-95
[14]韩文波.多层板结构超塑成形扩散连接工艺及数值模拟研究.哈尔滨工业大学博士论文,2004
[15]刘树桓。英国超塑成形与扩散连接技术的现状及特点。航空制造工程,1994,(1):21~22
[16]李志强.钛合金超塑成形/扩散连接四层夹层结构.航空科学技术.1995年,第6期
[17]刘劲松,肖寒,李毅波编著,MSC.MARC在材料加工工程中的应用,中国水利水电出版社
[18]马高山,曾元松,李志强,尚波生.超塑成形数值模拟中广义摩擦系数的研究.航空制造技术.2004,(1):79-82
[19]高庆峰。宽弦空心风扇叶片超塑成形的数值仿真研究.南京航空航天大学硕士论文.2008年。
[20]宋玉泉,赵军.超塑性自由胀形的解析理论。吉林工业大学学报,Vol2,No.3,1985,p245-255
[21]宋玉泉,赵军.薄板自由胀形极限分析及其最佳加载规律,吉林工业大学学报,No.3,1985,p262-268
[22]钢铁。宽弦空心风扇叶片结构设计及强度分析研究。南京航空航天大学硕士论文。2005年。
[23]徐先懂,宋述稳.SPF/DB在空心叶片制造中的应用.金属成形工艺,2002年,第6期
[24]王祝堂.超塑成形扩散焊接工艺近况.国外科技,1990年,第6期
[25]辛礼兵.磨损机理的研究与探讨.安徽职业技术学院学报.2006,(04)
[26]TanakaE, MurakamiSandIshikawah.Constitutive modeling of superplasticity taking Account of grain and cavity growth [J].MaterSciForum, 1997.21
[27]航空航天工业部,高效节能发动机文集编委会.《高效节能发动机文集》《第三分册》.航空工业出版社,1991年
[28]李英华等编著,超塑性板材气压成形模具的设计与计算,山西,山西技术,2007.5
[29]R.E.Dawson, D.G.Pashley, J.E.Melville.Technology of the Wide Chord Fan Blade.American Instituteof Aeronautics and Astronautics/ASME/SAE/ASEE, 22nd Joint Propulsion Conference, Huntsville, Alabama, USA, AIAA-86-1748, June, 1986
[30]张新芳.超塑成形/扩散连接技术在发动机上的应用.燃气涡轮试验与研究,1996年,第4期
[31]M.McElhone.The hollow wide chord fan blade (WCFB)-a stiffened metallic structure.The Seminar on Designing High-Performance Stiffened Structures, London, UK, June 29, 1999, p.45-57
[32]刘家富.涡扇发动机风扇叶片及其成形工艺.航空工艺技术,1999年,第2期
[33]侯冠群.宽弦空心风扇叶片制造工艺的发展.航空制造工程,1994年,第4期
[34]佟淑兰.罗-罗公司的宽弦风扇叶片.国际航空,1994年,第9期
[35]梁春华,杨锐.航空发动机宽弦空心风扇叶片的发展及应用.航空发动机,1999年,第2期
[36]G.A.Fitzgerald and T.Broughton.The Rolls-Royce wide chord fan blade. The 1st international Conference of the Titanium Development Association, an Francisco, CA, October.1986
[37]R.E.Dawson et al.Energy Efficient Engine–Shroudless,Hollow Fan Blade Technology.Report. Report NASA CR-165586, NASA-Lewis Research Center, 1981
[38]Zhao Bing and Li Zhiqiang.Three Dimensional FEM Simulation of Titanium Hollow Blade Forming.Process. Rare Metal Materials and Engineering, 2010, 39(6): 0963?0968.
[2]朱林奇。国外超塑成形_扩散连接技术发展现状。航宇材料工艺,1996年,第2期
[3]楚武利刘前智胡春波。航空叶片机原理。西北工业大学出版社,2009年6月。
[4]林兆荣.金属超塑性成形原理及应用.北京:航空工业出版社,1990。
[5]文九巴等编著.超塑性应用技术.机械工业出版社.2005年。
[6]张德荣,超塑性力学,北京:航空工业出版社,1990.1.
[7]Barry Pridham,Adam Marriott,Brian Ginty.Process Simulation of Superplastic Forming of Titanium Structure.SAE 2001-01-2624
[8]郭和平曾元松韩秀全李志强。飞机钛合金整体结构的超塑成形焊接组合工艺技术。北京航空制造工程研究所。
[9]侯冠群,尚波生.宽弦空心风扇叶片技术的发展.航空制造工程,2002年,第12期
[10]Zhao Bing,Li Zhiqiang,Hou Hongliang,Liao Jinhua,Bai Bingzhe.Three Dimensional FEM Simulation of Titanium Hollow Blade Forming Process2010-07.
[11]J.R. Williamson. Aerospace Applications of SPF/DB. Superplastic Forming of Structural Alloys,TMS- AIME, Warrendale, PA, 1982, pp.291-306
[12]Y.W.Xun, M.J.Tan.Applications of superplastic forming and diffusion bonding to hollow engine blade. Journal of Materials Processing Technology 99, 2000, p.80-85
[13]Kajbyshev, O.A; Galimov, A.K; Kruglov, A.A; Lutfullin, R.Ya; Safiullin, R.V.Numerical analysis of the hollow fan blade designs.Problemy Mashinostraeniya I Nadezhnos'ti Mashin,n 1,2004,p.90-95
[14]韩文波.多层板结构超塑成形扩散连接工艺及数值模拟研究.哈尔滨工业大学博士论文,2004
[15]刘树桓。英国超塑成形与扩散连接技术的现状及特点。航空制造工程,1994,(1):21~22
[16]李志强.钛合金超塑成形/扩散连接四层夹层结构.航空科学技术.1995年,第6期
[17]刘劲松,肖寒,李毅波编著,MSC.MARC在材料加工工程中的应用,中国水利水电出版社
[18]马高山,曾元松,李志强,尚波生.超塑成形数值模拟中广义摩擦系数的研究.航空制造技术.2004,(1):79-82
[19]高庆峰。宽弦空心风扇叶片超塑成形的数值仿真研究.南京航空航天大学硕士论文.2008年。
[20]宋玉泉,赵军.超塑性自由胀形的解析理论。吉林工业大学学报,Vol2,No.3,1985,p245-255
[21]宋玉泉,赵军.薄板自由胀形极限分析及其最佳加载规律,吉林工业大学学报,No.3,1985,p262-268
[22]钢铁。宽弦空心风扇叶片结构设计及强度分析研究。南京航空航天大学硕士论文。2005年。
[23]徐先懂,宋述稳.SPF/DB在空心叶片制造中的应用.金属成形工艺,2002年,第6期
[24]王祝堂.超塑成形扩散焊接工艺近况.国外科技,1990年,第6期
[25]辛礼兵.磨损机理的研究与探讨.安徽职业技术学院学报.2006,(04)
[26]TanakaE, MurakamiSandIshikawah.Constitutive modeling of superplasticity taking Account of grain and cavity growth [J].MaterSciForum, 1997.21
[27]航空航天工业部,高效节能发动机文集编委会.《高效节能发动机文集》《第三分册》.航空工业出版社,1991年
[28]李英华等编著,超塑性板材气压成形模具的设计与计算,山西,山西技术,2007.5
[29]R.E.Dawson, D.G.Pashley, J.E.Melville.Technology of the Wide Chord Fan Blade.American Instituteof Aeronautics and Astronautics/ASME/SAE/ASEE, 22nd Joint Propulsion Conference, Huntsville, Alabama, USA, AIAA-86-1748, June, 1986
[30]张新芳.超塑成形/扩散连接技术在发动机上的应用.燃气涡轮试验与研究,1996年,第4期
[31]M.McElhone.The hollow wide chord fan blade (WCFB)-a stiffened metallic structure.The Seminar on Designing High-Performance Stiffened Structures, London, UK, June 29, 1999, p.45-57
[32]刘家富.涡扇发动机风扇叶片及其成形工艺.航空工艺技术,1999年,第2期
[33]侯冠群.宽弦空心风扇叶片制造工艺的发展.航空制造工程,1994年,第4期
[34]佟淑兰.罗-罗公司的宽弦风扇叶片.国际航空,1994年,第9期
[35]梁春华,杨锐.航空发动机宽弦空心风扇叶片的发展及应用.航空发动机,1999年,第2期
[36]G.A.Fitzgerald and T.Broughton.The Rolls-Royce wide chord fan blade. The 1st international Conference of the Titanium Development Association, an Francisco, CA, October.1986
[37]R.E.Dawson et al.Energy Efficient Engine–Shroudless,Hollow Fan Blade Technology.Report. Report NASA CR-165586, NASA-Lewis Research Center, 1981
[38]Zhao Bing and Li Zhiqiang.Three Dimensional FEM Simulation of Titanium Hollow Blade Forming.Process. Rare Metal Materials and Engineering, 2010, 39(6): 0963?0968.