宽弦空心风扇叶片超塑成形的数值仿真研究
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摘要
超塑成形(SPF)是一种高效益、近无余量的先进制造技术,被广泛应用于航空、航天、兵器、汽车等领域。超塑成形过程是一个极其复杂的过程,不仅变形量大,而且成形过程及产品质量受材料性能、摩擦状况、工艺条件、模具结构及加工设备等多种因素的影响。长期以来人们主要是采用基于经验的试错方法进行工艺及模具设计,这使得产品的研发周期较长、费用高,并且产品的质量也不能得到完全的保障。随着计算机及数值计算方法的发展,以有限元法为代表的数值模拟技术已广泛应用于超塑成形过程分析中。利用有限元数值模拟技术可以在计算机上虚拟实现叶片超塑成形的全过程,对预测缺陷的产生、降低生产成本以及保证质量有十分重要的作用。
本文讨论了宽弦空心风扇叶片的结构特点和生产方法——超塑成形/扩散连接(SPF/DB)工艺,着重介绍了超塑成形/扩散焊接(SPF/DB)叶片结构及其选材的特点。与其它的生产工艺相比,SPF/DB工艺是先进空心风扇叶片的重要备选方案。根据金属超塑性成形原理,本文对模型空心叶片超塑成形进行了数值模拟的分析。采用ANSYS/LS-DYNA有限元软件对三层和四层板结构空心叶片的超塑成形过程进行模拟。分析结果表明不同的工艺设计参数对空心风扇叶片的超塑成形过程有很大的影响,同时,得到了最佳应变速率下加载的压力-时间曲线,上述研究结果对宽弦空心风扇叶片超塑成形试验的设计提供了理论的参考依据。
本文发展了宽弦空心风扇叶片超塑成形的数值模拟方法,为进一步的研究和工程应用提供理论依据和方法。
Superplastic forming (SPF) have been widely used in the automobile, aerospace and weapon industries owing to their high efficiency, no margin left advanced manufacturing technology , The SPF is a complex process, Which is affected by material properties, friction condition, technological conditions, structure of dies, and related equipments. So far, the design of technology and dies mainly depends on the engineering experience and involves repeated trial-and-errors. This will result in the long research period and high cost, and the quality of products also can't be guaranteed absolutely. With the development of computer technologies and numerical methods, the FEM (Finite Element Method) numerical calculation method has been widely used to simulate the SPF process, through which the deformation of the blade can be obtained. All of these can be very helpful to predict occurrence of the defects, to reduce the cost and to guarantee the quality of products.
The development of hollow wide chord fan blades is described in this paper. The mechanical characteristic of the fan blades, its manufacturing method SPF/DB(Superplastic Forming/Diffusion Bonding) with particular reference to structural and metallurgical characteristics are discussed. Comparing with the others, the SPF/DB fabrication process is an outstanding candidate for manufacturing advanced hollow blades. According to metal SPF principle,Finite element simulation is presented for the SPF hollow modal fan blades, using ANSYS/LS-DYNA to simulate the multilayer hollow fan blade SPF/DB process. The analysis result showed that the different design parameters have greatly affect on the hollow fan blades SPF process, The curve of the pressure-time is optimized. The results of the study provide a theoretical reference to the design of the SPF hollow fan blades experiments. A kind of the finite element simulation methods of SPF/DB hollow fan blades are developed in this paper as theoretical basis and methods for the further research and engineering applications.
本文讨论了宽弦空心风扇叶片的结构特点和生产方法——超塑成形/扩散连接(SPF/DB)工艺,着重介绍了超塑成形/扩散焊接(SPF/DB)叶片结构及其选材的特点。与其它的生产工艺相比,SPF/DB工艺是先进空心风扇叶片的重要备选方案。根据金属超塑性成形原理,本文对模型空心叶片超塑成形进行了数值模拟的分析。采用ANSYS/LS-DYNA有限元软件对三层和四层板结构空心叶片的超塑成形过程进行模拟。分析结果表明不同的工艺设计参数对空心风扇叶片的超塑成形过程有很大的影响,同时,得到了最佳应变速率下加载的压力-时间曲线,上述研究结果对宽弦空心风扇叶片超塑成形试验的设计提供了理论的参考依据。
本文发展了宽弦空心风扇叶片超塑成形的数值模拟方法,为进一步的研究和工程应用提供理论依据和方法。
Superplastic forming (SPF) have been widely used in the automobile, aerospace and weapon industries owing to their high efficiency, no margin left advanced manufacturing technology , The SPF is a complex process, Which is affected by material properties, friction condition, technological conditions, structure of dies, and related equipments. So far, the design of technology and dies mainly depends on the engineering experience and involves repeated trial-and-errors. This will result in the long research period and high cost, and the quality of products also can't be guaranteed absolutely. With the development of computer technologies and numerical methods, the FEM (Finite Element Method) numerical calculation method has been widely used to simulate the SPF process, through which the deformation of the blade can be obtained. All of these can be very helpful to predict occurrence of the defects, to reduce the cost and to guarantee the quality of products.
The development of hollow wide chord fan blades is described in this paper. The mechanical characteristic of the fan blades, its manufacturing method SPF/DB(Superplastic Forming/Diffusion Bonding) with particular reference to structural and metallurgical characteristics are discussed. Comparing with the others, the SPF/DB fabrication process is an outstanding candidate for manufacturing advanced hollow blades. According to metal SPF principle,Finite element simulation is presented for the SPF hollow modal fan blades, using ANSYS/LS-DYNA to simulate the multilayer hollow fan blade SPF/DB process. The analysis result showed that the different design parameters have greatly affect on the hollow fan blades SPF process, The curve of the pressure-time is optimized. The results of the study provide a theoretical reference to the design of the SPF hollow fan blades experiments. A kind of the finite element simulation methods of SPF/DB hollow fan blades are developed in this paper as theoretical basis and methods for the further research and engineering applications.
引文
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[41] K.S. Lee, H. Huh. Simulation of superplastic forming/diffusion bonding with finite-element analysis using the convective coordinate system, Journal of Materials Processing Technology(Netherlands). Vol. 89-90, pp. 92-98. 19 May 1999
[42] F. Jovane, An approximate analysis of the superplastic forming of thin circular diacular diaphragm, theory and experiments. International Journal of Mechanical Science,10,1968, p403-427
[43] G.C.Cornfield and R.H.Johnson. The forming of superplastic sheet metal, International Journal of Mechanical Science , No.12, 1970, p479-490
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[2]韩文波,张凯锋,王国峰.Ti-6Al-4V合金多层板结构的超塑成形/扩散连接工艺研究.航空材料学报,2005年,第12期
[3]刘善国.国外飞机先进制造技术发展趋势.航空科学技术,2003年,第4期
[4]李志强,郭和平.超塑成形/扩散连接技术的应用与发展现状.航空制造技术,2004年,第11期
[5]王哲.钛合金超塑成形/扩散连接技术在飞机结构上的应用.钛工业进展,1999年,第3期
[6]李志强,郭和平.超塑成形/扩散连接技术在航空航天工业中的应用.锻压技术,2005年,第1期
[7] Barry Pridham, Adam Marriott, Brian Ginty. Process Simulation of Superplastic Forming of Titanium Structure. SAE 2001-01-2624
[8]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
[9]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
[10]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
[11]佟淑兰.罗?罗公司的宽弦风扇叶片.国际航空,1994年,第9期
[12]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
[13] G. A. Fitzgerald and T. Broughton. The Rolls-Royce wide chord fan blade. The 1st International Conference of the Titanium Development Association, San Francisco, CA, October. 1986
[14] R.E. Dawson et al. Energy Efficient Engine– Shroudless, Hollow Fan Blade Technology Report. Report NASA CR-165586, NASA-Lewis Research Center, 1981
[15] R.E. Dawson, D.G. Pashley, J.E. Melville. Technology of the Wide Chord Fan Blade. American Institute of Aeronautics and Astronautics/ASME/SAE/ASEE, 22nd Joint Propulsion Conference, Huntsville, Alabama, USA, AIAA-86-1748, June,1986
[16] R.B. Kelly, Sean B. Leen, I.R. Pashby, Andrew R. Kennedy. The Measurement of Friction for Superplastic Forming of Ti-6Al-4V.Materials Science Forum Vols. 447-448 (2004) pp. 111-116
[17]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
[18] J. Cundy. Saving Fuel With the Wide Chord Fan. Aeronautical Journal of the Royal Aeronautical Society, August/September, 1983
[19] M. McElhone. The hollow wide chord fan blade (WCFB) - a stiffened metallic structure. The Seminar on Designing High-Performance Stiffened Structures, London, UK, June29, 1999,p.45-57
[20] H.Charles Heikkenen, Terry R. McNelley. Superplasticity in Aerospace,1988
[20]刘军.航空发动机研制中的叶片加工工艺探讨.航空发动机,2000年第3期
[22]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
[23] J.R. Williamson. Aerospace Applications of SPF/DB. Superplastic Forming of Structural Alloys, TMS-AIME, Warrendale, PA, 1982, pp. 291-306
[24] 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
[25] 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
[26]王祝堂.超塑成形扩散焊接工艺近况.国外科技,1990年,第6期
[27]曾炳玮,鈦合金超塑性成形及擴散接合技術研究.国立台湾大学机械工程学研究所硕士论文。2004.6
[28]章伟承.Ti-6AL-4V板料超塑性能研究.南京航空航天大学硕士论文.1989
[29] J. H.LEE,Y.J.SONG,D.H.SHIN,C.S.LEE. Microstructural evolution during superplastic bulge forming of Ti–6Al–4V alloy. Materials Science and Engineering A.1998 243
[30]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
[31]王存孝.TC4板材超塑成形后的力学性能分析.航空工艺技术,1994年,第5期
[32]陈恳.超塑用TC4钛合金板材在某型飞机上的应用.航空制造工程,1997年,第12期
[33]朱林崎.国外超塑成形/扩散连接技术发展现状.宇航材料工艺,1996年,第2期
[34]白秉哲,张卓民,郑卫东,唐汝平.美国超塑成形技术及应用.航天技术与民品,1999年,第1期
[35]张敬儒.原苏联的超塑成形/扩散连接工艺.航空制造工程,1992年,第4期
[36]宋飞灵.英国超塑成形技术的应用现状.航空工艺现状,1994年,第3期
[37]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
[38]文九巴等编著.超塑性应用技术.机械工业出版社.2005年
[39]韩文波,张凯锋,王国峰,吴德忠.钛合金四层板结构的超塑成形/扩散连接工艺及数值模拟研究.第九届全国塑性工程学术年会论文摘要集,2005年
[40]王卫英.超塑成形过程数值模拟技术研究及应用.博士学位论文.南京:南京航空航天大学,1998
[41] K.S. Lee, H. Huh. Simulation of superplastic forming/diffusion bonding with finite-element analysis using the convective coordinate system, Journal of Materials Processing Technology(Netherlands). Vol. 89-90, pp. 92-98. 19 May 1999
[42] F. Jovane, An approximate analysis of the superplastic forming of thin circular diacular diaphragm, theory and experiments. International Journal of Mechanical Science,10,1968, p403-427
[43] G.C.Cornfield and R.H.Johnson. The forming of superplastic sheet metal, International Journal of Mechanical Science , No.12, 1970, p479-490
[44] S.Tang, Mechanicals of superplasticity, Dix Hills, New York,1979
[45]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
[46]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
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