CN101254583A - 用于提高翼型件疲劳凹口性能的设备及方法 - Google Patents

用于提高翼型件疲劳凹口性能的设备及方法 Download PDF

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CN101254583A
CN101254583A CN200710305279.4A CN200710305279A CN101254583A CN 101254583 A CN101254583 A CN 101254583A CN 200710305279 A CN200710305279 A CN 200710305279A CN 101254583 A CN101254583 A CN 101254583A
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A·卢纳
J·L·米勒
W·T·丁韦尔
M·J·布伦克
W·L·英霍夫
P·蒙塞勒
D·R·龙巴多
A·P·伍德菲尔德
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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Abstract

本发明公开了一种用于提高翼型件疲劳凹口性能的设备及方法。其中，一种在翼型件(22)内降低疲劳裂纹的方法包括：提供翼型件(22)，该翼型件(22)具有与顶端(34)间隔开的根部(36)、间隔开的前缘(30)和后缘(32)、从前缘(30)向后缘(32)延伸的吸入侧(40)以及对置的从前缘(30)和后缘(32)延伸的压力侧(38)；克服弯曲载荷支承翼型件(22)。翼型件(22)通过使用抛光元件(42)而抛光，以便生成至少一个残余压应力的抛光部分(68)。该至少一个抛光部分(68)位于前缘(30)的邻近处并通过所选的偏置距离与前缘(30)隔开，以便避免前缘(30)的变形。

Description

用于提高翼型件疲劳凹口性能的设备及方法
技术领域
本发明总体上涉及抗疲劳和容损的部件以及制造这种部件的方法。
背景技术
诸如燃气涡轮发动机风扇和压缩机叶片的各种金属的、陶瓷的以及复合材料部件，易受到因疲劳和损伤(例如来自外来物体的撞击)而形成裂纹的影响。该损伤降低了零件的寿命，从而要求修理或更换。
众所周知，通过诱发部件内的残余压应力可保护其免于裂纹扩展。施加这些应力的方法包括喷丸处理、激光冲击处理(LSP)、针销撞击处理(pinch peening)以及低塑性抛光处理(LPB)。这些方法通常通过在待保护的免于裂纹扩展的区域(例如燃气涡轮发动机的压缩机叶片的前缘)上施加一“块”残余压应力而实现。然而，喷丸处理不利于表面加工，且即使是采用适当的工业标准控制系统也会产生多种压力变化。象压缩机翼型件的零件对于通过喷丸处理而产生的粗糙的表面加工而失去其有效性。而且，通过喷丸处理而施加的残余应力非常接近于零件表面。激光冲击处理因所需的试样制备、所用器材以及人员训练要求而会显得昂贵。此外，喷丸处理和激光冲击处理会是相对慢的过程。
发明内容
其中，现有技术的上述缺点通过本发明而得到解决，本发明根据一个方面提供了一种在翼型件内降低裂纹扩展的方法，其包括：提供翼型件，该翼型件具有与顶端分隔开的根部、分隔开的前缘和后缘、自前缘向后缘延伸的吸入侧(suction side)以及对置的从前缘和后缘延伸的压力侧；克服弯曲载荷支承翼型件；以及使用抛光元件对翼型件抛光，以便生成至少一个残余压应力的抛光部分，该至少一个抛光部分位于前缘的邻近处并通过所选的偏置距离与前缘隔开，以便避免前缘的变形。
根据本发明的另一个方面，一种用于燃气涡轮发动机的翼型件包括：与顶端分隔开的根部、分隔开的前缘和后缘、从前缘向后缘延伸的吸入侧以及对置的从前缘和后缘延伸的压力侧，其中，翼型件的厚度限定在压力侧和吸入侧之间；和至少一个残余压应力的抛光部分，其从所选的压力侧和吸入侧中的一个向内延伸。抛光部分位于前缘的邻近处并通过所选的偏置距离与前缘隔开，以便避免前缘的变形。
根据本发明的另一个方面，提供了一种用于抛光燃气涡轮叶片的设备，该燃气涡轮叶片具有榫接部和自此沿径向向外延伸的翼型件，该翼型件具有在根部和顶端之间延伸的对置的前缘和后缘。该设备包括：具有与压缩机叶片的榫接部互补的横向榫接开槽的基座，该横向榫接开槽形成在基座的上表面内；定位在榫接开槽后方并从基座向上延伸的梁，该梁包括大致面对榫接开槽的支承表面，其中，梁相对于榫接开槽定位成当叶片在固定装置内加载负荷时支承表面将接触并向翼型件后缘提供支承；以及用于靠着梁紧固翼型件的夹持机构。
附图说明
通过参照以下说明并结合附图将会更好地理解本发明，附图中：
图1为现有技术的压缩机叶片的透视图；
图2为本发明使用的抛光设备的透视图；
图3为根据本发明一个方面所构成的固定装置的透视图，该固定装置具有安装在其内的压缩机叶片；以及
图4为根据本发明一个方面进行处理的压缩机叶片一部分的放大的侧视图；以及
图5为根据本发明一个方面进行处理的压缩机叶片的透视图。
元件符号对照表：
  20   涡轮发动机压缩机叶片
  22   翼型件
  24   平台
  26   柄部
  28   榫接部
  30   前缘
  32   后缘
  34   顶端
  36   根部
  38   压力侧
  40   吸入侧
  42   抛光元件
  44   抛光头
  46   液压管线
  48   心轴
  50   多轴线数字控制的或计算机控制的操纵器
  52   固定装置
  54   基座
  56   横向榫接开槽
  58   前端
  60   梁
  61   后面
  62   成角度的支承表面
  63   后面
  64   L形夹持杆
  66   螺栓
  68   抛光部分
  70   线性段
具体实施方式
参照附图，其中，贯穿各个视图同样的标号表示相同的元件，图1示出了处理前的示范性燃气涡轮发动机压缩机叶片20。该部件仅用作可应用本发明方法的零件的示例。本发明同样适用于易受到因疲劳或损失而引起裂纹的其它类型的部件，例如压缩机定子翼片、风扇叶片、涡轮叶片、轴和转子、固定架、致动装置硬构件(actuatorhardware)等。该部件可由金属合金、陶瓷或复合材料(例如碳纤维复合材料)制成。通常，该叶片由基于钛、铁或镍的合金制成。市场上可买到的该种合金的示例包括Ti 6-4、Ti 6-2-4-2、A-286、C 450和In 718。压缩机叶片20包括翼型件22、平台24和柄部26。在该特定示例中，柄部26包括容纳在转动盘(未示出)开槽内的榫接部28。翼型件22具有前缘30、后缘32、顶端34、根部36、压力侧38以及与压力侧38对置的吸入侧40。
图2示出了根据本发明的用于处理压缩机叶片20的设备。该设备包括抛光元件42，该抛光元件42在本示例中为由碳化钨制成的直径大约为6毫米(0.2英寸)的球体。诸如圆柱形辊子的其它大小和形状以及不同材料，也能被采用。公知类型的抛光头44以对置的方式保持抛光元件42。通过液压管线46向抛光头供给的受压流体用于向抛光元件42施加流体静压力。抛光元件42还可机械地加载负荷。抛光头44安装在心轴48上，心轴48又由公知类型的多轴线数字控制的或计算机控制的操纵器50所承载。
图3示出了用于在抛光操作期间支承翼型件22的固定装置52，以便避免在翼型件内诱发弯曲应力。固定装置52包括具有横向榫接开槽56的基座54，榫接开槽56与压缩机叶片20的榫接部28互补。榫接开槽56形成在基座54靠近其前端58的上表面内。梁60定位在榫接开槽56的后方并从基座54向上延伸。梁60具有前表面61和后表面63，且包括在其前端具倒角或成角度的支承表面62。支承表面62通常相对于前面61定位成锐角。梁60定位成使得支承表面62当其在固定装置52内加载负荷时将会接触翼型件22的后缘32并向其提供支承。提供了用于将翼型件22夹持在梁60上的装置。在示出的实施例中，L形夹持杆64通过螺栓66紧固在梁60的上端。夹持杆64确保了翼型件22的后缘32在抛光操作期间如图3所示保持接触支承表面62。
通过使用抛光元件42抛光压缩机叶片20表面上的线或痕迹从而完成了抛光操作，并生成了具有残余压应力的抛光部分68，如图5所示。在示出的示例中，抛光部分68位于翼型件22的前缘30的顶端部，且具有距顶端34大约为3.18毫米(0.125英寸)的外边界。抛光部分68具有大约为58.75毫米(2,313英寸)的径向长度“R”和大约为6.4毫米(0.250英寸)的轴向长度“A”。翼型件22的前缘30的轮廓对气动效能具有重要影响。因此，为避免前缘30的变形，抛光部分68的界限自前缘30偏置预选距离“D”，例如大约0.76毫米(0.030英寸)。该距离“D”在图5中未按比例地示出。已经发现，抛光部分68的该位置提供了不干涉前缘轮廓的增强的疲劳凹口(fatigue notch)性能。
对于既定材料，抛光压力、抛光元件大小、单步进程(step over)、工具路径、抛光方法和抛光部分68位置的结合将决定疲劳凹口性能。图4中，示出的抛光元件42沿翼型件22的表面描绘出抛光路径“P”。应注意的是，为说明性目的路径P被非常夸大地示出。在该示例中，路径“P”包括布置成一系列S圈的多个线性段70。该路径具有通过抛光元件42和所施压力而决定宽度“W”的印迹(footprint)。线性段70通过步进距离“S”而隔开。在步进距离S小于宽度W时，线性段70将会出现重叠。所示实施例中使用的抛光压力大约为150巴(2175磅/平方英寸)而步进距离S大约为0.076毫米(0.003英寸)。抛光工具14的速度选择成使得总处理时间大约为1分钟。翼型件22当紧固在固定装置52内时同时在两侧抛光以便减小其扭曲。两侧同时抛光的结合，随同固定装置所提供的支承一起降低了处理过程中的扭曲。更具体地，翼型件22沿支承表面62的制约防止了抛光元件任何不对称的载荷以免在翼型件22内施加弯曲应力。
根据上述过程进行处理的压缩机叶片20的最终疲劳测试表明疲劳凹口性能相对于基准(未进行处理的)提高了差不多5倍，其具有小于大约0.75度的翼弦角度扭曲和至少大约为9％的表面冷加工计量。
上文中已描述了抗疲劳和抗损伤的部件以及用于制造该部件的方法。尽管已描述了本发明的特定实施例，但本领域技术人员显然明白此外可做出的各种改动仍未脱离本发明的精神和范围。因此，提供本发明优选实施例的上述说明以及用于实施本发明的最佳模式，仅为说明性的目的而非限制目的，本发明通过权利要求所限定。

Claims (10)

1.一种降低翼型件(22)内疲劳裂纹的方法，包括：
提供翼型件(22)，所述翼型件(22)具有与顶端(34)间隔开的根部(36)、间隔开的前缘(30)和后缘(32)、从所述前缘(30)向所述后缘(32)延伸的吸入侧(40)以及对置的从所述前缘(30)和所述后缘(32)延伸的压力侧(38)；
克服弯曲载荷支承所述翼型件(22)；和
使用抛光元件(42)对所述翼型件(22)抛光，以便生成至少一个残余压应力的抛光部分(68)，所述至少一个抛光部分(68)位于所述前缘(30)的邻近处并通过所选的偏置距离与所述前缘(30)隔开，以便避免所述前缘(30)的变形。
2.根据权利要求1所述的方法，其特征在于，所述偏置距离至少为大约0.76毫米。
3.根据权利要求1所述的方法，其特征在于，所述方法还包括在抛光步骤期间克服弯曲应力支承所述翼型件(22)。
4.根据权利要求3所述的方法，其特征在于，所述翼型件由固定装置所支承，所述固定装置包括接触所述翼型件(22)边缘的大致刚性的梁(60)。
5.根据权利要求1所述的方法，其特征在于，所述抛光元件(42)为通过流体静压力沿所述翼型件(22)加载负荷的转动球体。
6.一种用于燃气涡轮发动机的翼型件(22)，包括：
与顶端(34)间隔开的根部(36)，间隔开的前缘(30)和后缘(32)，从所述前缘(30)向所述后缘(32)延伸的吸入侧(40)，以及对置的从所述前缘(30)和所述后缘(32)延伸的压力侧(38)，其中，所述翼型件(22)的厚度限定在所述压力侧(38)和所述吸入侧(40)之间；以及
从所选的所述压力侧(38)和所述吸入侧(40)中的至少一个向内延伸的至少一个残余压应力的抛光部分(68)，所述抛光部分(68)位于所述前缘(30)的邻近处并通过所选的偏置距离与所述前缘(30)隔开，以便避免所述前缘(30)的变形。
7.根据权利要求6所述的翼型件(22)，其特征在于，所述偏置距离至少为大约0.76毫米。
8.根据权利要求6所述的翼型件(22)，其特征在于，所述抛光部分(68)具有大约为6.4毫米的轴向长度。
9.一种用于抛光燃气涡轮叶片的设备，所述燃气涡轮叶片具有榫接部(28)和自此沿径向向外延伸的翼型件(22)，所述翼型件(22)具有对置的在根部(36)和顶端(34)之间延伸的前缘(30)和后缘(32)，所述设备包括：
具有与所述压缩机叶片(20)的榫接部(28)互补的横向榫接开槽(56)的基座(54)，所述横向榫接开槽(56)形成在所述基座(54)的上表面内；
定位在所述榫接开槽(56)的后方并从所述基座(54)向上延伸的梁(60)，所述梁(60)包括总体上面对所述榫接开槽(56)的支承表面，其中，所述梁(60)相对于所述榫接开槽(56)定位成当所述叶片(20)在所述固定装置(52)内加载负荷时，所述支承表面(62)将接触并向所述翼型件(22)的所述后缘(32)提供支承；以及
用于靠着所述梁(60)紧固所述翼型件(22)的夹持机构。
10.根据权利要求9所述的设备，其特征在于，所述设备内的所述夹持机构包括安装在所述梁(60)上端的L形夹持杆(64)。
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