CN102169518A - Accurate forming method for precise-casting turbine blade die cavity - Google Patents

Accurate forming method for precise-casting turbine blade die cavity Download PDF

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Publication number
CN102169518A
CN102169518A CN 201110072878 CN201110072878A CN102169518A CN 102169518 A CN102169518 A CN 102169518A CN 201110072878 CN201110072878 CN 201110072878 CN 201110072878 A CN201110072878 A CN 201110072878A CN 102169518 A CN102169518 A CN 102169518A
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model
casting
blade
turbine blade
numerical simulation
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卜昆
张定华
董一巍
程云勇
黄魁东
窦杨青
窦杨柳
张现东
刘金钢
杨小宁
袁帅
傅蒋威
周丽敏
乔燕
张亮
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Northwestern Polytechnical University
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Northwestern Polytechnical University
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Abstract

The invention discloses an accurate forming method for a precise-casting turbine blade die cavity, which comprises the following steps: the casting system model of a turbine blade is designed according to the casting technique of the turbine blade and a casting test is implemented; a thermoelectric couple is adopted for measuring the actual temperatures of the front edge and back edge of the blade, a blade back and a blade cabin during casting and condensing processes, determining the heat exchange coefficients of an interface, implementing numerical simulation on the casting process, obtaining the deformation situations of turbine blade castings during the casting process, implementing numerical simulation on precise casting process after the anti-deformation treatment of the casting model, and finally whether a molded surface deviation value meets the precision requirements on the size tolerance of the castings or not is judged. The accurate forming method for a precise-casting turbine blade die cavity greatly improves the finished product rate of the turbine blade, and reduces the periods and times of die trial.

Description

The accurate method for shaping of smart casting Mould Cavity for Turbine Blade
Technical field
The present invention relates to a kind of method for shaping of mold cavity.
Background technology
Complicated hollow turbine vane is the core technology of high thrust-weight ratio engine, and this class turbo blade is because inner cooling structure complexity, aerodynamic configuration and the strictness of blade wall thickness dimension precision requirement, and the condition of work harshness is the key of aeromotor development.At present, hollow turbine vane generally adopts monocrystalline or crystallographic orientation not to have the surplus hot investment casting, and after high temperature alloy injected formwork, reducing with temperature can the generation drawdown deformation.The mold cavity that investment pattern precision casting adopts must be considered the compensation to the foundry goods drawdown deformation.Because turbo blade is the ill structure that a large amount of free form surfaces and complicated inner cavity are formed, it is non-linear that the inequality of dispelling the heat when therefore cooling off causes the contraction of foundry goods, heterogeneous.Thus, making the used precision casting mould of turbo blade becomes reseach of engine production and manufactures and designs the blade frock that the cycle is the longest, technical difficulty is maximum in preparing, and the cavity design of precision casting mould is to solve the accurately key link of control shape.
The principle of design of mold cavity be deformation place give an amount of anti-deformation with offset foundry goods solidifying with cooling procedure in drawdown deformation.The drawdown deformation of foundry goods is non-linear, and embodies in the mode of displacement field (distribution of blade casting deformation amount).How to obtain the displacement field of foundry goods, and with serve as according to the die cavity of optimizing mould, be a key that guarantees the smart contraction rule cun precision of blade.At present, the design of mold cavity is still adopted in X, Y, three directions of Z and is calculated profile according to the comprehensive shrinkage factor that linear method simply provides.Obvious this method has unreasonable part, because blade is complex-shaped, heat radiation inequality when causing the foundry goods cooling, thereby the distortion of blade each point and inconsistent must could obtain to meet the product of accuracy requirement through after the die trial that repairs a die repeatedly repeatedly.So the die trial of this coarse reversible deformation Treatment Design mold cavity often, the manufacturing cycle of mould is long, can not satisfy mould and produce short period, high-precision requirement.Along with software ANSYS is used for actual processing, the at present existing method for designing mould cavity that the reversible deformation of the numerical simulation means quantification handles (Chinese patent application number: 200710028749.7 of utilizing, June 22 2007 applying date), for improving the mould design efficiency, the minimizing manufacturing cycle plays a role.But still employing experience of the employed relaxation factor of reversible deformation algorithm determines that this kind method still is difficult to effectively be directly used in the process of manufacture.
Summary of the invention
In order to overcome the accurately deficiency of designing mould die cavity of prior art, the invention provides a kind of precision casting mould cavity design method based on numerical simulation, its result can be directly used in the design of turbo blade precision casting mould die cavity, solves the problem that the cycle is long, efficient is low, precision is low of present similar mould design.
The technical solution adopted for the present invention to solve the technical problems may further comprise the steps:
Step 1
Design the running gate system model of turbo blade according to the pouring technology of turbo blade.
Step 2
The running gate system model that adopts finite element method that step 1 is set up carries out dividing elements.
Step 3
The running gate system model that adopts step 1 to set up is poured into a mould experiment.Adopt the actual temperature at thermocouple measurement blade front and rear edge, blade back and leaf basin place in cast and process of setting, introduce formula
Figure BSA00000455828800021
As the mathematical model of finding the solution interface heat exchange coefficient.In the formula: T (h c) be the simulated temperature value, T 'For with T (h c) corresponding measurement temperature value, the thermocouple number of n for arranging, promptly unknown interface heat exchange coefficient number.Set up iterative relation formula T K+1=T k+ Δ T.In the formula: T K+1Be the k+1 time iteration result, T kBe the result of the k time iteration, the modified value when Δ T is the k time iteration is as the accounting temperature value T of numerical simulation (h c) with the absolute value of the difference of measuring temperature value | T k-T ' | require (can be taken as 10 less than specified accuracy -3) time, when promptly the iteration result levels off to the point for measuring temperature temperature, have
Figure BSA00000455828800022
, think that then the heat exchange situation in numerical simulation this moment conforms to actual, and then definite interface heat exchange coefficient h c
Step 4
Obtain accurate interface heat exchange coefficient by step 3, carry out the numerical simulation of casting process then, to obtain the turbo blade casting deformation situation in the casting process.At first apply the numerical simulation boundary condition, comprise the thermal physical property parameter of alloy material and formwork material, initial cast alloy temperature, end the interface heat exchange coefficient between alloy temperature, alloy material and the finish cast die shell of numerical evaluation, the constraint condition of model displacement.By finding the solution of essence casting process stress field, draw the stress distribution of smart each node of casting process turbo blade grid model, and then derive the displacement of each node, can set up the displacement field model.
Step 5
Based on the reversible deformation iterative formula
Figure BSA00000455828800023
Cast model is carried out reversible deformation to be handled.P in the formula 0(x 0, y 0) any coordinate of discrete point on the initial blade surface of expression,
Figure BSA00000455828800024
Expression any one discrete point coordinate on the mold cavity, K represents the shrinkage factor of discrete point correspondence, the used K of shrinkage by inspection is 1.012 in the time of can being taken as Mould Cavity for Turbine Blade here and repairing a die,
Figure BSA00000455828800031
The coordinate difference ratio of two discrete points on the section of the foundry goods sustained height of expression cast direction, W Xy(x 1, y 1) displacement variable between two discrete points of expression.
Step 6
Discrete point after obtaining the cast model discrete point carried out reversible deformation and handle in step 5 carries out obtaining the reversible deformation model behind the surface reconstruction, just the mold cavity model.In order to verify whether the mold cavity model meets the demands, under the prerequisite of process conditions identical and mould structure, carry out the numerical simulation of smart casting process with step 4.
Step 7
Reversible deformation model that step 6 is obtained and foundry goods design a model and obtain the profile departure of reversible deformation model behind the registration, judge whether the profile departure meets the accuracy requirement of the dimensional tolerance of casting.As meeting accuracy requirement, then final reversible deformation model is the die cavity of precision casting mould.As do not meet accuracy requirement, and repeating step 4~step 7 then, the model behind final reversible deformation model deformation meets accuracy requirement.
The invention has the beneficial effects as follows:, significantly improved the yield rate of turbo blade by optimal design to essence casting Mould Cavity for Turbine Blade; The cycle and the number of times of die trial have been reduced.This method has important significance for theories and using value to the design of mold cavity, this method has been avoided the shortcoming of traditional empirical design, have the advantages that the design cycle is short, precision is high, efficient is high, and the defective of mould design can be found and correct in real time on computers, shortened the cycle of mould development, reduce the mould design cost significantly, be particularly useful for not having the governed new product development of experience.This method is applicable to the design of aeromotor with the outer die cavity of turbo blade precision casting mould.With respect to the technology of patent 200710028749.7, it is unreliable to the invention solves present numerical simulation result, can only be qualitative and problem that can't be quantitative.Simultaneously all used different relaxation factors, improved the precision of reversible deformation compensation for each grid node.
The present invention is further described below in conjunction with drawings and Examples.
Description of drawings
Fig. 1 is a process flow diagram of the present invention.
Fig. 2 is smart casting Turbine Blade Model.
Fig. 3 is the running gate system model.
Fig. 4 is the thermopair distribution schematic diagram.
Embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment has provided detailed embodiment and process being to implement under the prerequisite with the technical solution of the present invention.But protection scope of the present invention is not limited to following embodiment.
Produce the design of the shaper die cavity of certain type aeroturbine blade, the embodiment step as shown in Figure 1:
Step 1
Adopt certain type turbo-power blade to carry out numerical simulation, as shown in Figure 2.Its major parameter is the long 101mm of blade, maximum chord length 59.21mm, maximum inscribed circle radius 5.67mm, leading-edge radius 4.22mm, trailing edge radius 1.27mm.Blade is selected second generation single crystal super alloy DD6 for use, and formwork is selected silica sand for use.According to casting feeding theory and practical production experience,, adopt the teeming formula, 3 one group at power blade design blade casting technique and running gate system.As shown in Figure 3.
Step 2
Adopt commercial finite element pre-processing software Hypermesh (product of U.S. Altair company) model to be carried out dividing elements based on non-uniform grid subdivision technology, at first the running gate system model is imported among the Hypermesh, it is dispersed is tetrahedron element, element quality satisfies general enterprise finite element analysis quality requirements, in the present embodiment, require the element quality more than 95% to satisfy: the unit warpage less than 5.0, length limit, unit ratio less than 5.0, deflection less than 60.0, the unit Jacobi is greater than 0.7.Tetrahedron element sum 1,640,000 5 thousand.
Step 3
The running gate system of utilizing step 1 to set up is provided with a temperature field experiment, and the actual measurement turbo blade is in the temperature field of cast and process of setting.Utilize peg wood to substitute the thermopair fixed position after wax-pattern makes, then reserve the preset holes of thermopair behind the system shell in the fixed position.The riding position of thermopair as shown in Figure 4.Experiment is provided with 14 groups of thermopairs of common layout, measures the temperature variation data of blade tenon, blade, seeding section respectively.Wherein, the seeding section is laid 4 groups of thermopairs altogether, 1,5,6, No. 10 thermopair as shown in Figure 4, and 1, No. 10 thermocouple measurement seeding section bottom temp is measured seeding section spiral place temperature No. 5, measures seeding section and blade junction temperature No. 6.The blade section is laid 7 groups of thermopairs, and 2, No. 3 thermopairs are placed in blade leaf basin axis as shown in Figure 4, and 7,8, No. 9 thermopair is positioned at the trailing edge place, and 11, No. 12 thermopair is positioned at blade blade back axis.Tenon is laid 3 groups of thermopairs, and No. 4 thermopairs as shown in Figure 4 are positioned at the blade axis, is positioned at same horizontal line with No. 4 thermopairs 13, No. 14, and two groups of thermopair institute locations put identically, but No. 13 depth positions are shallow than No. 14 thermocouples.According to the thermocouple location arrangement that experiment is adopted, can measure the thermograde of blade process of setting, the temperature contrast of going back the same level height diverse location of energy measurement (leaf basin, blade back, trailing edge) simultaneously.Adopt the gravity-assist pouring mode.Pouring temperature is 1550 ℃, and experiment has been carried out the temperature field actual measurement to six groups of blades.Data acquisition time 4000 seconds, collecting temperature variation range are 1550 ℃-600 ℃.The anti-module of asking based on ProCAST (product of French ESI Group), the input measured value, through 15 iteration, the counter curve of asking the coefficient of heat transfer t conversion in time that obtains foundry goods and formwork, the function that obtains the interface coefficient of heat transfer between foundry goods and formwork through the curve match is expressed: h Foundry goods-formwork=12160.36+1245.61t -0.52
Step 4
Adopt ProCAST that turbo blade is carried out smart casting process numerical simulation, alloy is selected the DD6 high-temperature nickel-base alloy for use, and its liquidus temperature is 1380 ℃, and solidus temperature is 1310 ℃.Its pyroconductivity is 33.2W/mK, and density is 8780kg/m 3, specific heat is 99.0KJ/Kg/K.Formwork is selected silica sand for use, and its pyroconductivity is 0.59W/mK, and density is 1520kg/m 3, specific heat is 1.20KJ/Kg/K.The alloy initial temperature of numerical simulation is 1550 ℃, and the alloy temperature of numerical simulation termination of computations is 600 ℃.Interface heat exchange coefficient between alloy and the formwork is selected the calculated value of embodiment step 3.Displacement constrains is that running channel bottom and blade seeding section bottom fixing and cold copper bottom is fixing.
Step 5
Based on the reversible deformation iterative formula
Figure BSA00000455828800051
Cast model is carried out reversible deformation to be handled.In the formula Discrete point on the expression mold cavity, K represents the shrinkage factor of each discrete point correspondence.Be 1.012, The coordinate difference ratio of two discrete points on the expression section line, W Xy(x 1, y 1) expression discrete point displacement variable, P 0(x 0, y 0) expression initial blade profile discrete point coordinate.
Step 6
Discrete point after pin obtains the cast model discrete point carried out reversible deformation and handle in step 5 obtains the reversible deformation model after using the surface reconstruction function under the UG (product of Siemens), just the mold cavity model.In order to verify whether the mold cavity model meets the demands, under the prerequisite of process conditions identical and mould structure, carry out the numerical simulation of smart casting process with step 4.
Step 7
The reversible deformation model that step 6 is obtained is by UG software File menu " importing " function importing UG platform down, designs a model with foundry goods and obtains the profile departure of reversible deformation model behind the registration.Whether the model behind the detection reversible deformation model deformation meets the foundry goods accuracy requirement.As meet accuracy requirement, then according to final reversible deformation distorted pattern, design the die cavity of precision casting mould.As do not meet accuracy requirement, and then proceed foundry goods reversible deformation processing and numerical simulation, the model behind final reversible deformation model deformation meets accuracy requirement.

Claims (1)

1. the accurate method for shaping of smart casting Mould Cavity for Turbine Blade is characterized in that comprising the steps:
Step 1
Design the running gate system model of turbo blade according to the pouring technology of turbo blade;
Step 2
The running gate system model that adopts finite element method that step 1 is set up carries out dividing elements;
Step 3
The running gate system model that adopts step 1 to set up is poured into a mould experiment; Adopt the actual temperature at thermocouple measurement blade front and rear edge, blade back and leaf basin place in cast and process of setting, introduce formula As the mathematical model of finding the solution interface heat exchange coefficient, in the formula: T (h c) be the simulated temperature value, T 'For with T (h c) corresponding measurement temperature value, the thermocouple number of n for arranging; Set up iterative relation formula T K+1=T k+ Δ T is in the formula: T K+1Be the k+1 time iteration result, T kBe the result of the k time iteration, the modified value when Δ T is the k time iteration is as the accounting temperature value T of numerical simulation (h c) with the absolute value of the difference of measuring temperature value | T k-T ' | when requiring, T is arranged less than specified accuracy K+1=T ' thinks that then the heat exchange situation in numerical simulation this moment conforms to actual, and then definite interface heat exchange coefficient h c
Step 4
Obtain accurate interface heat exchange coefficient by step 3, carry out the numerical simulation of casting process then, to obtain the turbo blade casting deformation situation in the casting process: at first apply the numerical simulation boundary condition, comprise the thermal physical property parameter of alloy material and formwork material, initial cast alloy temperature, end the interface heat exchange coefficient between alloy temperature, alloy material and the finish cast die shell of numerical evaluation, the constraint condition of model displacement; By finding the solution of essence casting process stress field, draw the stress distribution of smart each node of casting process turbo blade grid model, and then derive the displacement of each node, can set up the displacement field model.
Step 5
Based on the reversible deformation iterative formula Cast model is carried out reversible deformation handle P in the formula 0(x 0, y 0) any coordinate of discrete point on the initial blade surface of expression,
Figure FSA00000455828700013
Any one discrete point coordinate on the expression mold cavity, K represents the shrinkage factor of discrete point correspondence, getting K is 1.012,
Figure FSA00000455828700014
The coordinate difference ratio of two discrete points on the section of the foundry goods sustained height of expression cast direction, W Xy(x 1, y 1) displacement variable between two discrete points of expression;
Step 6
Discrete point after obtaining the cast model discrete point carried out reversible deformation and handle in step 5 carries out obtaining the mold cavity model behind the surface reconstruction; Under the prerequisite of process conditions identical and mould structure, carry out the numerical simulation of smart casting process with step 4;
Step 7
Reversible deformation model that step 6 is obtained and foundry goods design a model and obtain the profile departure of reversible deformation model behind the registration, judge whether the profile departure meets the accuracy requirement of the dimensional tolerance of casting; As meeting accuracy requirement, then final reversible deformation model is the die cavity of precision casting mould; As do not meet accuracy requirement, and repeating step 4~step 7 then, the model behind final reversible deformation model deformation meets accuracy requirement.
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CN113414347A (en) * 2021-07-01 2021-09-21 上海万泽精密铸造有限公司 Method for controlling dimensional accuracy of hollow blade wax mold
CN115047160A (en) * 2022-04-28 2022-09-13 上海交通大学 Device and method for evaluating casting performance of single crystal high-temperature alloy
CN115047160B (en) * 2022-04-28 2023-11-03 上海交通大学 Device and method for evaluating casting performance of monocrystal superalloy
CN116638061A (en) * 2023-06-14 2023-08-25 广州市型腔模具制造有限公司 Die casting size deformation control method for new energy automobile
CN116638061B (en) * 2023-06-14 2023-11-21 广州市型腔模具制造有限公司 Die casting size deformation control method for new energy automobile

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Application publication date: 20110831