高温合金薄壁叶片铣削加工变形基础研究
发布时间：2018-08-03 06:41
【摘要】：叶片是航空发动机的核心部件之一,在实现发动机的能量转换上有着重要作用。作为一类典型的薄壁结构件,叶片在其加工中存在让刀变形、切削颤振等问题,从而影响加工精度,缩短刀具使用寿命。为了适应高温高压环境,涡轮燃烧室中的叶片材料多采用高温合金。由于高温合金的切削加工性较差,加上薄壁叶片曲面特征复杂、刚性差等特点,使得这类叶片的加工难度增大、加工质量难以保证。本文以高温合金薄壁叶片为研究对象,结合铣削试验和有限元仿真,对GH2132静子叶片的加工变形情况进行了深入的研究,并提出了相应的加工变形控制策略。论文主要研究工作如下:(1)通过正交试验建立了高温合金立铣削过程中两种峰值切削力预测模型,(fz,ap,ae)模型和(hm,ap)模型;通过试验验证了预测模型的准确性;通过单因素试验研究了铣削参数对切削力的影响规律,为高温合金的铣削参数优选提供了依据;通过MATLAB编程实现了切削用量的快速选择。(2)基于峰值铣削力预测模型和试验研究,建立了叶片加工变形有限元仿真模型,通过仿真计算得到了铣削参数和装夹方式对叶片加工变形量的影响,结合工程力学理论分析验证了仿真结果的合理性;对薄壁叶片型面进行了铣削加工,验证了参数优选和装夹方式优化的有效性。(3)采用有限元法和轮廓法对高温合金GH2132静子叶片毛坯的初始残余应力进行了测量和评估,通过对比分析得到了叶片毛坯的应力场分布,轮廓法测试结果与有限元计算结果表现出一定的一致性,运用有限元仿真研究了初始残余应力对叶片铣削加工变形的影响。
[Abstract]:Blade is one of the core components of aero-engine, and plays an important role in the realization of engine energy conversion. As a kind of typical thin-walled structure, the blade has the problems of deforming the cutter and cutting chatter, which affects the machining accuracy and shortens the service life of the tool. In order to adapt to the high temperature and high pressure environment, the blade materials in the turbine combustor are mostly superalloy. Due to the poor machinability of the superalloy, the complicated surface features of thin-walled blade and the poor rigidity, the machining difficulty of this kind of blade is increased and the machining quality is difficult to guarantee. In this paper, the machining deformation of GH2132 stator blade is studied with milling test and finite element simulation, and the corresponding deformation control strategy is put forward. The main research work of this paper is as follows: (1) two kinds of peak cutting force prediction models, (fzapae) model and (hmap) model, are established by orthogonal test, and the accuracy of the prediction model is verified by experiments The influence of milling parameters on cutting force is studied by single factor test, which provides the basis for the optimization of milling parameters of superalloy, and realizes the rapid selection of cutting parameters by MATLAB programming. (2) based on the prediction model of peak milling force and experimental research, The finite element simulation model of blade machining deformation is established, and the influence of milling parameters and clamping mode on blade machining deformation is obtained by simulation calculation. The rationality of simulation results is verified by engineering mechanics theory analysis. The effectiveness of parameter optimization and clamping optimization is verified by milling thin-walled blade surface. (3) the initial residual stress of GH2132 stator blade blank is measured and evaluated by finite element method and contour method. The stress field distribution of blade blank is obtained by contrast analysis. The results of contour method and finite element method show some agreement. The effect of initial residual stress on blade milling deformation is studied by finite element simulation.
【学位授予单位】：南京航空航天大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG54
本文编号：2160850
[Abstract]:Blade is one of the core components of aero-engine, and plays an important role in the realization of engine energy conversion. As a kind of typical thin-walled structure, the blade has the problems of deforming the cutter and cutting chatter, which affects the machining accuracy and shortens the service life of the tool. In order to adapt to the high temperature and high pressure environment, the blade materials in the turbine combustor are mostly superalloy. Due to the poor machinability of the superalloy, the complicated surface features of thin-walled blade and the poor rigidity, the machining difficulty of this kind of blade is increased and the machining quality is difficult to guarantee. In this paper, the machining deformation of GH2132 stator blade is studied with milling test and finite element simulation, and the corresponding deformation control strategy is put forward. The main research work of this paper is as follows: (1) two kinds of peak cutting force prediction models, (fzapae) model and (hmap) model, are established by orthogonal test, and the accuracy of the prediction model is verified by experiments The influence of milling parameters on cutting force is studied by single factor test, which provides the basis for the optimization of milling parameters of superalloy, and realizes the rapid selection of cutting parameters by MATLAB programming. (2) based on the prediction model of peak milling force and experimental research, The finite element simulation model of blade machining deformation is established, and the influence of milling parameters and clamping mode on blade machining deformation is obtained by simulation calculation. The rationality of simulation results is verified by engineering mechanics theory analysis. The effectiveness of parameter optimization and clamping optimization is verified by milling thin-walled blade surface. (3) the initial residual stress of GH2132 stator blade blank is measured and evaluated by finite element method and contour method. The stress field distribution of blade blank is obtained by contrast analysis. The results of contour method and finite element method show some agreement. The effect of initial residual stress on blade milling deformation is studied by finite element simulation.
【学位授予单位】：南京航空航天大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG54
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