航空叶片模具设计参数对模具磨损影响分析
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摘要
为解决航空叶片精锻模具磨损严重,设计参数确定困难等问题,本文在分析模具设计过程和锻造工艺的基础上,基于Archard摩擦理论,借助有限元分析软件对不同设计参数的叶片模具的精锻成形过程进行了模拟仿真,运用正交试验设计方法分析了模具成形角度、桥部厚度、桥部宽度对叶片成形力和模具磨损的影响,得出了有益于叶片成形和减小模具磨损的最优化组合设计参数,并对该参数的计算方法进行了改进,简化了计算过程且参数计算更加精确;最后,通过工程实例对上述过程进行了验证,其实验结果与仿真结果的一致性较好,减小了模具磨损,提高了叶片模具设计效率.
To solve the problem of serious wear of air blade precision forging die and the difficulty in determining design parameters, the precision forming process of blade die with different design parameters were simulated by the finite element analysis software on the basis of the analysis of die design process, forging process, and the Archard friction theory. The influence of die forming angle, bridge thickness, and bridge width on blade forming force and die wear was analyzed by orthogonal test design method. The optimal combination design parameters which benefited the blade forming and reduced the die wear were obtained and the calculation method of the parameters was improved, which made the calculation process more simple and the parameter calculation more accurate. Finally, the above process was verified by engineering examples. The experimental results were in good agreement with the simulation results, which reduced the die wear and improved the efficiency of the blade die design.
To solve the problem of serious wear of air blade precision forging die and the difficulty in determining design parameters, the precision forming process of blade die with different design parameters were simulated by the finite element analysis software on the basis of the analysis of die design process, forging process, and the Archard friction theory. The influence of die forming angle, bridge thickness, and bridge width on blade forming force and die wear was analyzed by orthogonal test design method. The optimal combination design parameters which benefited the blade forming and reduced the die wear were obtained and the calculation method of the parameters was improved, which made the calculation process more simple and the parameter calculation more accurate. Finally, the above process was verified by engineering examples. The experimental results were in good agreement with the simulation results, which reduced the die wear and improved the efficiency of the blade die design.
引文
[1] 刘维伟.航空发动机叶片关键制造技术研究进展[J].航空制造技术,2016,516(21):50-56.LIU Weiwei.Research progress on key manufacturing technology of aeroengine blades[J].Aeronautical Manufacturing Technology,2016,516(21):50-56.DOI:10.16080/j.issn1671-833x.2016.21.050
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[10] GAO Tao,YANG He,LIU Yuli.Backward tracing simulation of precision forging process for blade based on 3D FEM[J].Transactions of Nonferrous Metals Society of China,2006,16(2):639-644.
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[12] 孙宪萍,刘强强,杨兵,等.基于磨损正交试验的温挤压模具优化设计[J].润滑与密封,2016,41(6):73-76.SUN Xianping,LIU Qiangqiang,YANG Bing,et al.Optimization design on warm extrusion die based on orthogonal experiments of wear[J].Lubrication Engineering,2016,41(6):73-76.DOI:10.3969/j.issn.0254-0150.2016.06.016
[13] 占亮,李霞,孙礼宾,等.基于正交试验的曲轴热锻工艺参数优化[J].锻造技术,2014,39(7):10-13.ZHAN Liang,LI Xia,SUN Libin,et al.Design optimization of process parameters of crankshaft die forging based on orthogonal experiment[J].Forging & Stamping Technology,2014,39(7):10-13.DOI:10.13330/j.issn.1000-3940.2014.07.003
[14] BARIANI P F,BRUSCHI S,DAL NEGRO T.Integrating physical and numerical simulation techniques to design the hot forging process of stainless steel turbine blades[J].International Journal of Machine Tools and Manufacture,2004,44(9):945-951.
[15] XU L,YAN P G,HUANG H Y,et al.Numerical simulation of the final stage nozzle blade with dolphin profile in the steam turbine[J].Jilin Daxue Xuebao,2008,38:28-33.
[16] WANG X J,LIAO G L,ZHU D,et al.Numerical simulation on suction performance of steam turbine hollow stationary blade[J].Turbine Technology,2012(3):195-197.
[17] 齐广霞,曹娜,史丽坤.GH4169合金叶片终锻成形宏观场量规律数值模拟[J].锻造技术,2011,36(5):155-162.QI Guangxia,CAO Na,SHI Likun.Laws of macro-field numerical simulation in GH4169 alloy blade final forging[J].Forging & Stamping Technology,2011,36(5):155-162.
[18] 郑丹星.流体与过程热力学[M].北京:化学工业出版社,2010.
[19] 《透平机械现代制造技术丛书》编委会.叶片制造技术[M].北京:科学出版社,2002.
[2] 余小鲁,李付国.TC4钛合金风扇转子叶片模锻工艺和性能研究[J].锻造技术,2010,35(3):19-21.YU Xiaolu,LI Fuguo.Research on die forging process and mechanical properties of titanium alloy TC4 fan propeller blade [J].Forging & Stamping Technology,2010,35(3):19-21.
[3] AMANO C X R S.On the development of turbo machine blade aerodynamic design system[J].International Journal for Computational Methods in Engineering Science & Mechanics,2009,10(3):186-196.
[4] JHAVAR S,PAUL C P,JAIN N K.Causes of failure and repairing options for dies and molds[J].Engineering Failure Analysis,2013,9(36):1-7.
[5] KIM D H,LEE H C,KIM B M,et al.Estimation of die service life against plastic deformation and wear during hot forging processes[J].Journal of Materials Processing Technology,2005,166(3):372-380.
[6] KIM B M,LEE H C,KIM K H.Estimation of die service life in hot forging,considering lubricants and surface treatments[J].Proceedings of the Institution of Mechanical Engineers.Part B:Engineering Manufacture,2003,217(7):1011-1022.
[7] YANG Hai,ZHANG Dinghua,LI Shan,et al.Research and application of collaboration between design & manufacturing for precision forged blade[J].Advanced Materials Research,2012,490-495:2534-2539.
[8] LEE R S,JOU J L.Application of numerical simulation for wear analysis of warm forging die[J].Journal of Materials Processing Technology,2003,140:43-48.
[9] BEHRENS B A,BOUGUECHA A,HADIFI T,et al.Numerical and experimental investigations on the service life estimation for hot-forging dies[J].Key Engineering Materials,2012,504-506:163-168.
[10] GAO Tao,YANG He,LIU Yuli.Backward tracing simulation of precision forging process for blade based on 3D FEM[J].Transactions of Nonferrous Metals Society of China,2006,16(2):639-644.
[11] JIA W P,XIN L,JING C,et al.Temperature/stress field numerical simulation of hollow blade produced by laser rapid forming[J].Chinese Journal of Lasers,2007,34(9):1308-1312.
[12] 孙宪萍,刘强强,杨兵,等.基于磨损正交试验的温挤压模具优化设计[J].润滑与密封,2016,41(6):73-76.SUN Xianping,LIU Qiangqiang,YANG Bing,et al.Optimization design on warm extrusion die based on orthogonal experiments of wear[J].Lubrication Engineering,2016,41(6):73-76.DOI:10.3969/j.issn.0254-0150.2016.06.016
[13] 占亮,李霞,孙礼宾,等.基于正交试验的曲轴热锻工艺参数优化[J].锻造技术,2014,39(7):10-13.ZHAN Liang,LI Xia,SUN Libin,et al.Design optimization of process parameters of crankshaft die forging based on orthogonal experiment[J].Forging & Stamping Technology,2014,39(7):10-13.DOI:10.13330/j.issn.1000-3940.2014.07.003
[14] BARIANI P F,BRUSCHI S,DAL NEGRO T.Integrating physical and numerical simulation techniques to design the hot forging process of stainless steel turbine blades[J].International Journal of Machine Tools and Manufacture,2004,44(9):945-951.
[15] XU L,YAN P G,HUANG H Y,et al.Numerical simulation of the final stage nozzle blade with dolphin profile in the steam turbine[J].Jilin Daxue Xuebao,2008,38:28-33.
[16] WANG X J,LIAO G L,ZHU D,et al.Numerical simulation on suction performance of steam turbine hollow stationary blade[J].Turbine Technology,2012(3):195-197.
[17] 齐广霞,曹娜,史丽坤.GH4169合金叶片终锻成形宏观场量规律数值模拟[J].锻造技术,2011,36(5):155-162.QI Guangxia,CAO Na,SHI Likun.Laws of macro-field numerical simulation in GH4169 alloy blade final forging[J].Forging & Stamping Technology,2011,36(5):155-162.
[18] 郑丹星.流体与过程热力学[M].北京:化学工业出版社,2010.
[19] 《透平机械现代制造技术丛书》编委会.叶片制造技术[M].北京:科学出版社,2002.