文生琼,刘岩,徐云龙,等.基于ProCAST仿真的型芯型壳一体化空心涡轮叶片反变形精度控制[J].精密成形工程,2024,16(12):116-123.
WEN Shengqiong,LIU Yan,XU Yunlong,et al.Precision Control of Anti-deformation for Hollow Turbine Blades Using Integrated Core-shell Technology Based on ProCAST[J].Journal of Netshape Forming Engineering,2024,16(12):116-123. |
| 基于ProCAST仿真的型芯型壳一体化空心涡轮叶片反变形精度控制 |
| Precision Control of Anti-deformation for Hollow Turbine Blades Using Integrated Core-shell Technology Based on ProCAST |
| 投稿时间：2024-03-20 |
| DOI：10.3969/j.issn.1674-6457.2024.12.009 |
| 中文关键词: 空心涡轮叶片 反变形 型面精度 一体化铸型 3D打印 凝胶注模 |
| 英文关键词: hollow turbine blade anti-deformation surface accuracy integrated casting mold 3D printing gel-casting |
| 基金项目:国家重大专项(J2019-Ⅶ-0013-0153) |
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| 摘要点击次数: 122 |
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| 中文摘要: |
| 目的 针对空心涡轮叶片在定向凝固铸造过程中产生收缩扭转变形的问题，对叶片进行反变形补偿优化，控制叶片铸造过程中的型面精度，实现空心涡轮叶片的快速迭代。方法 通过ProCAST仿真软件对某型号空心涡轮导叶进行定向凝固模拟浇铸及位移场偏差分析，根据分析结果采用分截面反变形法对叶片进行整体重构;基于光固化3D打印技术与凝胶注模技术制备型芯/型壳一体化的反变形重构叶片铸型;对铸型内部结构进行CT检测并使用高温合金DZ411完成浇铸验证。结果 反变形后叶片铸件尾缘最大偏差值从0.435 mm降低为0.120 6 mm，叶盆方向最大扭转值从0.134 mm降低为0.097 1 mm，前缘最大偏差值由0.206 mm降低为0.085 mm，提高了浇铸叶片的型面精度;气动性能分析结果表明，反变形收缩扭转的叶型基本保持了原叶片性能。结论 通过反变形优化后的空心涡轮导叶整体偏差降低，实现了空心涡轮叶片型面的精度控制;利用型芯/型壳一体化技术的快速性缩短了叶片型面精度优化周期，为未来新型空心涡轮叶片的快速制造奠定了一定的工艺基础。 |
| 英文摘要: |
| The work aims to optimize the blades through reverse deformation compensation to control the surface accuracy during the casting process and achieve rapid iteration of hollow turbine blades, to solve the shrinkage and torsional deformation of hollow turbine blades during directional solidification casting. ProCAST simulation software was used to conduct directional solidification simulation casting and displacement field deviation analysis on a certain model of hollow turbine blades. Based on the analysis results, the blade was reconstructed as a whole using the sectional reverse deformation method. Based on the UV curing 3D printing technology and gel casting technology, an integrated core/shell mold of reverse deformation blades was prepared. CT inspection was performed on the internal structure of the mold and casting verification was completed using high-temperature alloy DZ411. After reverse deformation, the maximum deviation value of the trailing edge of the blade casting decreased from 0.435 mm to 0.120 6 mm, the maximum torsion value in the blade basin direction decreased from 0.134 mm to 0.097 1 mm, and the maximum deviation value at the front edge decreased from 0.206 mm to 0.085 mm, improving the surface accuracy of the cast blade. The aerodynamic performance analysis results showed that the anti-deformation, contraction, and torsion blade profile basically maintained the original blade performance. In conclusion, the overall deviation of the hollow turbine guide vanes is reduced through anti-deformation optimization, achieving precision control of the hollow turbine blade profile. The rapid use of integrated core/shell technology shortens the optimization cycle of blade surface accuracy, laying a certain process foundation for the rapid manufacturing of new hollow turbine blades in the future. |
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