CN102426622A - Adaptive variable-speed drawing simulation method for production of single-crystal blade - Google Patents
Adaptive variable-speed drawing simulation method for production of single-crystal blade Download PDFInfo
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Abstract
The invention discloses an adaptive variable-speed drawing simulation method for production of a single-crystal blade, belonging to the technical field of material processing. The method is characterized in that through simulating a process of producing the single-crystal blade of a turbine engine through directional solidification based on a Bridgeman method, the evolution process of temperature field and tissue growth in the solidification process of a cast product after molten metal casting and during the running process of a drawing mechanism is simulated completely; meanwhile, under the guide of the simulation result of the temperature field and the tissue growth in the solidification process and based on the industrial standard requirements on production of the single-crystal blade, change time and change degree of drawing speed in the solidification process can be determined by adopting a neural network algorithm and a PID (Proportion Integration Differentiation) control principle so as to optimize a drawing speed technique in the full-blade solidification process. By the adoption of the method, the yield of production of cast products is improved, the production efficiency is enhanced, the process debugging cycle and production cost are reduced, and a single-stage variable-speed drawing process for producing the single-crystal blade through directional solidification is upgraded to an adaptive multi-stage variable-speed drawing process; and therefore, the method has wide application prospect.
Description
Technical Field
The invention relates to a self-adaptive variable-speed pulling method for single crystal blade production, in particular to a method for establishing a speed curve of a variable-speed pulling process of a single crystal blade by adopting a numerical simulation technology.
Background
The turbine single crystal blade has important application in the aviation and civil fields, and can be used as a guide blade of an aircraft engine, a turbine blade or a blade of a civil gas engine. The manufacturing technique of the single crystal blade is also regarded by experts in the material processing direction of various countries. At present, the production of single crystal blades is divided into a fixed-speed drawing process and a variable-speed drawing process only from the perspective of the speed process, and the characteristics of the two processes are compared as follows:
the comparison result of the two drawing speed processes can be obtained as follows:
1. the constant-speed drawing process has been developed and matured, can be stably used for producing single crystal blades, and successfully applies the numerical simulation technology to industrial production; however, the constant-speed drawing process has inherent disadvantages of low productivity, high cost, difficult processing of parts with partially complex shapes (such as large abrupt cross sections) and the like, and cannot be developed for a long time, and gradually exits from industrial application, and finally can be completely replaced by the variable-speed drawing process;
2. the variable-speed drawing process belongs to the development stage at present and is gradually applied to actual production, the drawing speed process is flexibly designed, the production efficiency and the product percent of pass are improved, and the process is suitable for the scientific process requirements of low carbon and environmental protection. China can develop single crystal blades by itself, but the yield of the single crystal blades is far from the high yield of blade production of the American P & W company, the GE company and the British Roro company. Currently, the determination of the variable speed process curve mainly faces the following difficulties: the process determination needs a great deal of debugging, the speed change time and the size determination lack sufficient theoretical basis, although the numerical simulation technology is introduced for optimization analysis, the speed change time and the depth are still determined in advance by experience, and the advantages of the numerical simulation technology are not fully exerted. At present, a single-stage speed change process is widely adopted in production, and the research and practice about multi-stage speed change are not reported yet.
A feasible method is provided, a set of drawing speed change curve v (t) along with time can be reasonably and quickly provided, the production efficiency is improved again, the process debugging period and the cost are greatly reduced, and the method is a necessary way for the development of the directional solidification process for producing the single crystal blade.
Disclosure of Invention
The invention aims to provide a self-adaptive pulling speed method for single crystal blade production, which optimizes the pulling speed of a single crystal blade production process by using a numerical simulation technology and taking an industrial qualified standard as a guide, provides a pulling speed change curve v (t) along with time, reduces the process debugging period, reduces the cost, reasonably improves the production efficiency and solves the problem of determining the multi-stage change pulling speed for producing single crystal blades.
The idea of the invention is as follows: the self-adaptive variable-speed pulling method for producing the single crystal blade firstly realizes the test simulation of the blade solidification process, and the test simulation combines the experiment temperature measurement result to correct and determine the basic parameters for simulation suitable for the current furnace body equipment; and then entering a prediction simulation stage, aiming at outputting a drawing speed time-varying curve v (t) suitable for the actual single crystal production blade through simulation calculation, in the prediction simulation process, preliminarily determining the drawing speed time-varying curve according to the single crystal blade section variation condition by adopting a neural network algorithm, then carrying out drawing speed optimization, finishing the drawing speed optimization calculation according to a speed change criterion and a speed change rule, and finally outputting a set of drawing speed time-varying curve v (t) meeting the actual blade production requirement, wherein the speed change criterion takes the heat flow direction of a unit, the liquid phase solidification surface position and a mixed crystal nucleus as investigation standards, and the speed change rule is divided into a speed reduction rule and a speed increase rule which optimize the drawing speed according to a PID control principle.
The invention is characterized by comprising the following steps in sequence:
step (1), constructing a computer-experimental device system based on a numerical simulation method:
the experimental device comprises: a directional solidification furnace and a tungsten/rhenium thermocouple, wherein:
a furnace body of the directional solidification furnace is simplified into a heating area positioned at the upper part and a cooling area positioned at the lower part which are separated by a baffle, a drawing mechanism of the cooling area is formed by connecting a circular crystallizer and a drawing push rod, a blade shell for casting is arranged on the circular crystallizer, the blade shell passes through a hole on the baffle under the action of the drawing mechanism and can reciprocate up and down between the heating area and the cooling area, temperature measuring points are set at least 6 points corresponding to a crystal leading section, a spiral crystal selection section, a blade body, an upper edge plate, a lower edge plate and a tenon of a single crystal blade in a cavity of the blade shell, the baffle is horizontally connected at the middle positions of two sides of a furnace wall in the directional solidification furnace,
a tungsten/rhenium thermocouple, the output end of which inputs the temperature of the corresponding temperature measuring point to the computer when measuring the temperature of the temperature measuring point of the blade shell,
the computer is preset with FT-Star software;
step (2), carrying out the self-adaptive variable-speed drawing simulation process for producing the single crystal blade according to the following steps in sequence:
step (2.1), the operator inputs basic parameters for simulation of the material used for the production of the single crystal blade into the computer,
which comprises the following steps: heat transfer coefficient, radiative heat transfer coefficient, physical parameters of the alloy used: specific heat, latent heat, density and solid/liquid phase line temperature, directional solidification furnace parameters: the diameter and the height of the heating area, the diameter and the height of the cooling area, the thickness of the baffle plate and the diameter of the disc crystallizer are input, meanwhile, a fixed drawing speed value is input to be 3mm/min,
step (2.2), the operator inputs the three-dimensional simplified model of the single crystal blade shell into the computer, the computer carries out three-dimensional discretization on the cubic unit for the three-dimensional simplified model by using the FT-Star software,
step (2.3), an operator sends an instruction of testing and simulating the temperature field of the blade solidification process by using the FT-Star software to the computer to obtain and output data of time variation of the simulated temperature values of the at least 6 temperature measuring points in the step (1),
step (2.4), an operator takes the single crystal blade as a sample wafer, takes 3mm/min as a fixed drawing speed value, carries out a pouring experiment in the experimental device under the same basic parameter condition for simulation in the step (2.1), and measures the actual temperature change data of each temperature measuring point along with the time in real time,
step (2.5), the operator compares and analyzes the data of the temperature measurement points obtained by numerical simulation in step (2.3) under the condition of the same time with the temperature data of the temperature measurement points actually measured in step (2.4), at any same time, if the relative temperature error delta of one temperature measurement point is greater than 10%, the heat conduction coefficient and the radiation heat exchange coefficient value determined last time need to be increased or decreased by 10% respectively, and the values are input into the FT-Star software as new basic parameters until the relative temperature errors of all the temperature measurement points at different times are not greater than 10%, so as to determine the basic parameters finally used for simulation calculation, wherein the relative temperature errors refer to: the ratio of the absolute value of the difference between the temperature analog value and the temperature measured value to the temperature measured value,
and (2.6) performing predictive simulation on the adaptive variable-speed drawing process for producing the single crystal blade in a computer according to the following steps:
step (2.6.0), a three-dimensional model of the single crystal blade shell for actual production is established, FT-Star software is adopted to carry out three-dimensional discretization, discretized discrete subunits are represented as C (i, j, k), i, j and k are coordinate values of the discrete subunits,
step (2.6.1), setting a drawing speed curve v (t), wherein v (t) represents a drawing speed value at the time t:
step (2.6.11), determining a shift criterion: the speed change criterion is used for determining when to change the drawing speed value and comprises two criteria: the deceleration criterion and the acceleration criterion are defined as follows:
a mushy zone, which is a zone between a solid phase temperature line and a liquid phase temperature line in the blade shell in the solidification process;
liquid-phase solidification surface: an interface where the liquid phase begins to solidify in the mushy zone;
Sk tthe ratio of the area of the liquid phase solidification surface of the mushy zone to the average sectional area of the mushy zone at the time t, the average sectional area of the mushy zone is 10 equal divisions of the mushy zone along the z direction, and the sectional area value of each equal division point is obtained, so as to obtain the average value of the sectional areas of the equal division points,
SMis Sk tThe optimum value of (a), taken here as 1.2;
ziuestablishing a z-direction one-dimensional coordinate system along the directional solidification drawing direction by taking the center of the baffle as the origin of coordinates, wherein z isiuThe coordinates of the upper end surface of the baffle plate are obtained;
zidestablishing a z-direction one-dimensional coordinate system along the directional solidification drawing direction by taking the center of the baffle as the origin of coordinates, wherein z isidThe coordinates of the lower end face of the baffle plate are obtained;
zSLthe mean value of the z-direction coordinates of the centers of the discrete subunits on the liquid-phase solidification surface;
Enin the mushy zone, in the region from liquid-phase solidification surface to liquidus isothermal surface, the sign of whether the mixed crystal nucleation occurs or not, if so, EnTrue 1, otherwise En＝False＝0；
1) First deceleration criterion 1, Sk t＞SM，Sk tThe drawing speed is higher than the optimal value, which indicates that the liquid phase solidification surface is seriously bent due to the overlarge drawing speed;
or, the second deceleration criterion 2, zSL＜zidThe average value of the liquid-phase solidification surface is positioned below the baffle, which shows that the drawing speed is too high, the heat dissipation is not timely, and the position of the liquid-phase solidification surface is lowered;
or, the third deceleration criterion 3, EnWhen True is 1, the paste area is deeply overcooled, which causes mixed crystal nucleation;
2) criterion for acceleration, zSL＞ziu，
Step (2.6.1.2) of determining the sectional area series values S of the 5 bar-shaped sample models0And a respective maximum withdrawal speed VmaxThe functional relationship of (a) to (b),
step (2.6.1.2.1), establishing a first group of 5 rod-shaped sample models with different cross sections, wherein the length of all the rod-shaped sample models is 300mm, and the rod-shaped sample models are used as a first group of standard calculation examples and are marked as marksQuasi-model series 1, S078.5, 314.2, 1256.6, 1963.5, 2827.4, unit: mm is2Wherein S is0As a series of sectional area values of the bar-like specimen model,
a step (2.6.1.2.2) of calculating the maximum drawing speed V of the model of the bar-like samplemax：
Performing three-dimensional discretization on the rod-shaped sample models with the 5 different cross sections by adopting the FT-Star software, respectively performing simulation calculation on the rod-shaped sample models with the 5 different cross sections by taking the determined basic parameters for simulation in the step (2.5) as input quantities, and changing the drawing speed by taking the speed change criterion in the step (2.6.1.1) as the basis, wherein when the calculated data meet the speed change criterion, the absolute value of the speed increment reduced or increased every time is 1mm/min, continuously judging until the determined drawing speed does not meet the speed change criterion and the solidification is completely finished, and at the moment, the determined drawing speed value is the maximum drawing speed value VmaxThereby establishing a series S of sectional area values corresponding to 5 sample models of the standard model series 10And a maximum drawing speed VmaxThe relationship pair of (1): [ S ]0(n)-Vmax(n)]，n＝1，2，3，4，5，
Step (2.6.1.2.3), according to the relation pair [ S ] of step (2.6.1.2.2)0(n)-Vmax(n)]Using BP neural network algorithm, with S0For input layer variables, with VmaxFor outputting layer variables, carrying out system training on the first group of standard examples according to the relation pair to obtain an inline relation between input quantity and output quantity, namely
F(S0)＝[Vmax]
Wherein, F (S)0) Shows the unified functional relationship determined by the BP neural network algorithm according to the 5 bar-shaped sample models of the first set of standard algorithms,
step (2.6.1.3) of determining a mutated section [ S [ ]1∶S2]And a maximum drawing speed vmaxAndfunctional relationship between shift timing advance Δ t:
step (2.6.1.3.1) of creating a second set of 5 cross-section-mutated bar-like specimen models, which are recorded as a second set of standard calculation examples as a standard model series 2, [ S ]1∶S2]314.2: 706.9, 314.2: 1256.6, 314.2: 1963.5, 706.9: 1963.5, 1256.6: 2827.4, units: mm is2∶mm2All the bar-shaped sample models had a length of 300mm and a position z of the initial mutation of the cross section of 150mm,
S1the cross-sectional area value before cross-sectional change is represented by z1，
S2The cross-sectional area value after the cross-section change is shown as z along the z-direction coordinate2，
And satisfy, z1＜z＜z2，(z2-z1)/z＜5％，
Step (2.6.1.3.2), determining a maximum pull rate versus time curve for each bar model of the second set of standard calculations by:
step (2.6.1.3.2.1) of adopting the maximum speed formula F (S) of step (2.6.1.2.3)0)＝[Vmax]When the sectional area is changed, the drawing speed is correspondingly changed according to the functional relation,
and (2.6.1.3.2.2) determining the relation between the maximum drawing speed and time, and determining the time of the speed change point as t according to the set section starting mutation position z as 150mm1＝z/v1，t2＝z/v2Wherein
v1The area before the abrupt change of the cross section is S1The corresponding maximum drawing speed value is obtained,
v2the area is S after the section is suddenly changed2The corresponding maximum drawing speed value is obtained,
the drawing speed profile thus determined is given by v1Drawing at speed and duration t1Again, the velocity value is changed to start with v2Drawing at speed and duration t2，
And (2.6.1.3.3) according to the calculation simulation, correcting the variation relation of the maximum drawing speed of the second group of standard calculation examples along time: taking the curve of the maximum drawing speed determined in the step (2.6.1.3.2.2) along with the change of time as input, adopting the FT-Star software to carry out simulation calculation, and combining the speed change criterion to judge, when the speed change criterion is met, not changing the speed value, but reducing the speed change point time t1The reduction amount is 0.5min each time, the calculation is carried out again until the solidification is finished, all time reduction values are accumulated and recorded as delta t, and finally the corresponding relation pair of each model in the second group of standard calculation examples is determined: [ S ]1(n)∶S2(n)-v1(n)∶v2(n)∶Δt(n)]，n＝1，2，3，4，5，
A step (2.6.1.3.4) of applying BP according to the relation pair of the step (2.6.1.3.3)
Neural network algorithm with S1，S2As input layer variables, with v1，v2And delta t is an output layer variable, and the second standard example is subjected to system training to obtain an inline relation between input quantity and output quantity, namely
F(S1，S2)＝[v1，v2，Δt]
Wherein, F (S)1，S2) Showing the passage of 5 bar-shaped sample models according to the second set of standard examples
The BP neural network algorithm determines a unified functional relationship,
step (2.6.1.4), analyzing sectional area values of different sections according to the three-dimensional model of the actual blade shell, calculating a required drawing speed time-varying curve according to the sectional area, speed and time function relation determined in the step (2.6.1.3.4),
step (2.6.2), optimizing the solidification drawing speed curve v (t): taking the basic parameters for simulation determined in the step (2.5) as input, taking the three-dimensional discretization model established in the step (2.6.0) as input, taking the drawing speed variation curve with time established in the step (2.6.1) as input, adopting FT-Star software to perform simulation calculation, and adopting a speed change criterion to perform speed change judgment, wherein the speed change method when the criterion is met comprises the following steps:
the method comprises the following steps of automatically optimizing drawing speed, adjusting speed change quantity and speed change time point, determining the speed change quantity of each speed change according to a speed change rule, and dividing the speed change rule into two parts, namely a speed reduction rule and a speed increase rule:
a deceleration rule: z is a radical ofSL＜zid
a) When the deceleration criterion 1 is satisfied, the deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
Wherein,
Sk tand SMThe definition is shown in the step (2.6.1.1),
tprtthe time of the current coagulation,
tbfwhen the temperature value of the unit with the current mushy zone at the solidus line is reduced to the liquidus temperature from the casting starting temperature, the corresponding time point satisfies tbf＜tprt，
vmIs tbfThe speed value corresponding to the moment of time,
Lmthe speed is decreased by the adjustment factor,
b) when the deceleration criterion 2 is satisfied, the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zidSpeed reductionTime position: the program back-off time Δ t is 3min,
wherein,
zSLand zidThe definition is shown in the step (2.6.1.1),
vmis tbfThe speed value corresponding to the moment of time,
tbfthe temperature value of the unit with the current mushy zone at the solidus line is reduced from the initial casting temperature to the liquidus temperature
The time corresponding to t is satisfiedbf＜tprt，
c) When the deceleration criterion 3 is satisfied, Δ vm＝(1-Lm)vm，Lm＝10％；
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
d) When both the deceleration criterion 1 and the deceleration criterion 2 are fulfilled,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: amount of program backoff time Δ t1＝tprt-tbf，
Calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Let, Δ Vmin＝(ΔVm∶Δvm)，Δtmin＝(Δt1∶Δt2)，
Wherein,
ΔVminis Δ VmAnd ΔvmThe minimum value of the sum of the average values,
Δtminis Δ t1And Δ t2The minimum value of the sum of the average values,
when both the deceleration criterion 1 and the deceleration criterion 3 are fulfilled,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SMCalculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝10％；
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
Let, Δ Vmin＝(ΔVm∶Δvm)，
Wherein,
ΔVminis Δ VmAnd Δ vmThe minimum value of the sum of the average values,
when both the deceleration criterion 2 and the deceleration criterion 3 are fulfilled,
calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Calculating deceleration quantity delta v ″m＝(1-Lm)vm，Lm＝10％；
Deceleration time position: amount of program backoff time Δ t3＝tprt-tbf，
Let, Δ Vmin＝(Δvm∶Δv`m)，Δtmin＝(Δt2∶Δt3)，
Wherein,
ΔVminis Δ vmAnd Δ v ″mThe minimum value of the sum of the average values,
Δtminis Δ t2And Δ t3The minimum value of the sum of the average values,
when the deceleration criterion 1, the deceleration criterion 2 and the deceleration criterion 3 are simultaneously satisfied,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: amount of program backoff time Δ t1＝tprt-tbf，
Calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Calculating deceleration quantity delta v ″m＝(1-Lm)vm，Lm＝10％；
Deceleration time position: amount of program backoff time Δ t3＝tprt-tbf，
Let, Δ Vmin＝(ΔVm∶Δvm∶Δv`m)，Δtmin＝(Δt1∶Δt2∶Δt3)，
Wherein,
ΔVminis Δ Vm、ΔvmAnd Δ v ″mThe minimum value of the sum of the average values,
Δtminis Δ t1、Δt2And Δ t3The minimum value of the sum of the average values,
the amount of pull-out speed reduction is thus Δ VminThe deceleration time position is delta tmin，
B, speed increasing rule: when the criteria for acceleration are met,
acceleration amount Δ vp＝(1+Lp)vp，Lp＝(zSL-ziu)/ziu，
Speed-increasing time position: the current time is increased in speed,
wherein L ispThe speed is increased by the adjustment factor,
step (2.6.3), when the calculation result is verified according to the speed change criterion, the full-blade solidification is satisfied
And (d) drawing a curve according to the speed and the time during the beam forming process to obtain a v (t) solidification drawing speed curve.
The self-adaptive variable-speed drawing method for producing the single crystal blade has the following advantages: a neural network algorithm is adopted, the influence of the sectional area S and the sectional position k on a drawing speed curve is considered, and a fixed speed change curve is prefabricated; a speed change criterion is proposed, the bending degree of a solid-liquid interface in a mushy zone in the solidification process is taken as a judgment content, and 3 speed reduction criteria and 1 speed increase criterion are proposed by combining the position of the solid-liquid interface relative to a baffle and the mechanism of appearance of mixed crystals, so that the time space position for speed change is determined; and providing a speed change rule which comprises a speed reduction rule and a speed increase rule, wherein the speed change rule takes a PID control principle as guidance, and the speed change variable and the speed change time are determined according to the speed change rule in the calculation process.
Drawings
Figure 1 is a simplified mathematical schematic of a directional solidification apparatus,
in the figure: 0-directional solidification furnace wall; 1-directional solidification furnace body heating zone; 2-a baffle plate; 3-directional solidification furnace body cooling zone; 4-a blade module; 5-pulling the push rod; 6-single blade; 7-disc-shaped crystallizer.
FIG. 2 is a general flow diagram of a method for producing an adaptive variable speed pulling of a single crystal blade.
FIG. 3 is a flow chart of speed determination for an adaptive variable speed pulling method for producing single crystal blades.
Figure 4 schematic view of the temperature measurement point position of the blade shell,
figure 4.1 schematic front view of the temperature measurement point position of the blade shell,
figure 4.2 side schematic view of the temperature measurement point position of the blade shell,
in the figure: 8-the position of the No. 1 temperature measuring point of the crystal initiator; 9-the position of a No. 2 temperature measuring point of the spiral crystal selector; 10-position of No. 3 temperature measuring point of lower edge plate; 11-position of No. 4 temperature measuring point of blade body; 12-the position of the No. 5 temperature measuring point on the upper edge plate; 13-number 6 temperature measurement point position of tenon.
FIG. 5 is a schematic diagram of a solidified mushy zone of a single crystal blade.
Detailed Description
The principle, structure and process of the present invention will be further described with reference to the accompanying drawings.
Fig. 1 is a simplified mathematical schematic diagram of a directional solidification apparatus based on the bridgman directional solidification method, the apparatus is simplified and divided into a furnace wall 0, a heating zone 1, a baffle 2 and a cooling zone 3, wherein the heating zone 1 continuously heats a blade part in the solidification process, the cooling zone 3 cools the blade part entering the zone in the solidification process, the baffle 2 is responsible for isolating the heating zone 1 and the cooling zone 3 to improve the temperature gradient, a blade module 4 is generally 6 blade shell modules or 3 blade shell modules, a drawing push rod 5 and a disc crystallizer 7 are connected to form a drawing mechanism of the furnace body together, and the speed change process is completed by a main drawing mechanism.
FIG. 2 is a general flow chart of a single crystal blade production adaptive variable speed pulling method, the single crystal blade production adaptive variable speed pulling method of the present invention first constructs a computer-experimental device system based on numerical simulation, then gradually inputs basic physical property parameters used for simulation and a three-dimensional discretization model of the blade, and tests and simulates the blade production at a constant pulling speed of 3mm/min to obtain a temperature time-varying curve of the solidification process; carrying out an actual pouring experiment and measuring temperature, wherein the drawing speed is still selected to be 3mm/min, so as to obtain an actually-measured temperature time-varying curve, comparing and analyzing the temperature curves obtained by simulation and experiment, correcting the simulation parameters when the error exceeds a certain value, and continuously calculating until the temperature curve calculated by the corrected simulation parameters and the actual error do not exceed the specified limit, and determining the simulation parameters; establishing a three-dimensional discretization model of the actual blade, establishing a functional relation between sectional area change and drawing speed, preliminarily determining a drawing speed change curve according to the sectional area change and the sectional area change position of the model, then optimizing the preliminarily determined drawing speed in real time through simulation calculation, and finally outputting a drawing speed time-varying curve suitable for the actual blade.
FIG. 3 is a flow chart of speed determination of the adaptive variable-speed pulling method for single crystal blade production, which comprises the steps of firstly primarily determining a pulling speed curve v (t), establishing a first group of standard examples according to a variable-speed criterion, and obtaining a sectional area S according to the variable-speed criterion0And a maximum drawing speed VmaxThe second set of standard calculation examples is established to determine the functional relation between the cross section area and the maximum drawing speed and the time lead under the condition of the abrupt cross section, namely F (S)1，S2)＝[v1，v2，Δt]According to the functional relation, establishing a drawing speed curve v (t) for the actual blade three-dimensional model; secondly, optimizing a drawing speed curve v (t), optimizing the drawing speed in the calculation process according to a speed change rule, changing the speed curve when the speed change rule is met in the calculation process, and completing the changing method according to the speed change rule which adopts a PID control principle and is divided into a speed reduction rule and a speed increase rule; and when the calculation does not meet the speed change criterion and the final solidification is finished, outputting a final drawing speed curve v (t) by a program, and finishing the self-adaptive speed change drawing method.
FIG. 4 is a schematic view of the location of the temperature measurement point of the blade shell,
the temperature measurement experiment selects 6 representative temperature measurement points, wherein the temperature measurement points comprise a No. 1 temperature measurement point of a crystal initiator 8, a No. 2 temperature measurement point of a spiral crystal selector 9, a No. 3 temperature measurement point of a lower edge plate 10, a No. 4 temperature measurement point of a blade body middle part 11, a No. 5 temperature measurement point of an upper edge plate 12 and a No. 6 temperature measurement point of a tenon 13.
Claims (1)
1. The self-adaptive variable-speed drawing simulation method for producing the single crystal blade is characterized by sequentially comprising the following steps of:
step (1), constructing a computer-experimental device system based on a numerical simulation method:
the experimental device comprises: a directional solidification furnace and a tungsten/rhenium thermocouple, wherein:
a furnace body of the directional solidification furnace is simplified into a heating area positioned at the upper part and a cooling area positioned at the lower part which are separated by a baffle, a drawing mechanism of the cooling area is formed by connecting a circular crystallizer and a drawing push rod, a blade shell for casting is arranged on the circular crystallizer, the blade shell passes through a hole on the baffle under the action of the drawing mechanism and can reciprocate up and down between the heating area and the cooling area, temperature measuring points are set at least 6 points corresponding to a crystal leading section, a spiral crystal selection section, a blade body, an upper edge plate, a lower edge plate and a tenon of a single crystal blade in a cavity of the blade shell, the baffle is horizontally connected at the middle positions of two sides of a furnace wall in the directional solidification furnace,
a tungsten/rhenium thermocouple, the output end of which inputs the temperature of the corresponding temperature measuring point to the computer when measuring the temperature of the temperature measuring point of the blade shell,
the computer is preset with FT-Star software;
step (2), carrying out the self-adaptive variable-speed drawing simulation process for producing the single crystal blade according to the following steps in sequence:
step (2.1), the operator inputs to said computer the basic parameters for the simulation of the material used for the production of the single crystal blade, among which: heat transfer coefficient, radiative heat transfer coefficient, physical parameters of the alloy used: specific heat, latent heat, density and solid/liquid phase line temperature, directional solidification furnace parameters: the diameter and the height of the heating area, the diameter and the height of the cooling area, the thickness of the baffle plate and the diameter of the disc crystallizer are input, meanwhile, a fixed drawing speed value is input to be 3mm/min,
step (2.2), the operator inputs the three-dimensional simplified model of the single crystal blade shell into the computer, the computer carries out three-dimensional discretization on the cubic unit for the three-dimensional simplified model by using the FT-Star software,
step (2.3), an operator sends an instruction of testing and simulating the temperature field of the blade solidification process by using the FT-Star software to the computer to obtain and output data of time variation of the simulated temperature values of the at least 6 temperature measuring points in the step (1),
step (2.4), an operator takes the single crystal blade as a sample wafer, takes 3mm/min as a fixed drawing speed value, carries out a pouring experiment in the experimental device under the same basic parameter condition for simulation in the step (2.1), and measures the actual temperature change data of each temperature measuring point along with the time in real time,
step (2.5), the operator compares and analyzes the data of the temperature measurement points obtained by numerical simulation in step (2.3) under the condition of the same time with the temperature data of the temperature measurement points actually measured in step (2.4), at any same time, if the relative temperature error delta of one temperature measurement point is greater than 10%, the heat conduction coefficient and the radiation heat exchange coefficient value determined last time need to be increased or decreased by 10% respectively, and the values are input into the FT-Star software as new basic parameters until the relative temperature errors of all the temperature measurement points at different times are not greater than 10%, so as to determine the basic parameters finally used for simulation calculation, wherein the relative temperature errors refer to: the ratio of the absolute value of the difference between the temperature analog value and the temperature measured value to the temperature measured value,
and (2.6) performing predictive simulation on the adaptive variable-speed drawing process for producing the single crystal blade in a computer according to the following steps:
step (2.6.0), a three-dimensional model of the single crystal blade shell for actual production is established, FT-Star soft discretization is adopted, discretized discrete subunits are expressed as C (i, j, k), i, j and k are coordinate values of the discrete subunits,
step (2.6.1), setting a drawing speed curve v (t), wherein v (t) represents a drawing speed value at the time t:
step (2.6.11), determining a shift criterion: the speed change criterion is used for determining when to change the drawing speed value and comprises two criteria: the deceleration criterion and the acceleration criterion are defined as follows:
a mushy zone, which is a zone between a solid phase temperature line and a liquid phase temperature line in the blade shell in the solidification process;
liquid-phase solidification surface: an interface where the liquid phase begins to solidify in the mushy zone;
Sk tthe ratio of the area of the liquid phase solidification surface of the mushy zone to the average sectional area of the mushy zone at the time t, the average sectional area of the mushy zone is 10 equal divisions of the mushy zone along the z direction, and the sectional area value of each equal division point is obtained, so as to obtain the average value of the sectional areas of the equal division points,
SMis Sk tThe optimum value of (a), taken here as 1.2;
ziuestablishing a z-direction one-dimensional coordinate system along the directional solidification drawing direction by taking the center of the baffle as the origin of coordinates, wherein z isiuThe coordinates of the upper end surface of the baffle plate are obtained;
zidestablishing a z-direction one-dimensional coordinate system along the directional solidification drawing direction by taking the center of the baffle as the origin of coordinates, wherein z isidThe coordinates of the lower end face of the baffle plate are obtained;
zSLthe mean value of the z-direction coordinates of the centers of the discrete subunits on the liquid-phase solidification surface;
Enin the mushy zone, the mark indicating whether the heteromorphism nucleation occurs or not in the region from the liquid phase solidification surface to the liquidus isothermal surface, if the heteromorphism nucleation occurs, EnTrue 1, otherwise En＝False＝0；
1) First deceleration criterion 1, Sk t＞SM，Sk tThe drawing speed is higher than the optimal value, which indicates that the liquid phase solidification surface is seriously bent due to the overlarge drawing speed;
or, the second deceleration criterion 2, zSL＜zidThe average value of the liquid-phase solidification surface is positioned below the baffle, which shows that the drawing speed is too high, the heat dissipation is not timely, and the position of the liquid-phase solidification surface is lowered;
or, the third deceleration criterion 3, EnWhen True is 1, the paste area is deeply overcooled, which causes mixed crystal nucleation;
2) criterion for acceleration, zSL＞ziu，
Step (2.6.1.2) of determining the sectional area series values S of the 5 bar-shaped sample models0And a respective maximum withdrawal speed VmaxThe functional relationship of (a) to (b),
step (2.6.1.2.1), a first group of 5 rod-shaped sample models with different cross sections is established, the lengths of all the rod-shaped sample models are 300mm, and the rod-shaped sample models are used as a first group of standard calculation examples and are recorded as a standard model series 1, S078.5, 314.2, 1256.6, 1963.5, 2827.4, unit: mm is2Wherein S is0As a series of sectional area values of the bar-like specimen model,
step (ii) of(2.6.1.2.2), calculating the maximum drawing speed V of the rod-shaped sample modelmax：
Performing three-dimensional discretization on the rod-shaped sample models with the 5 different cross sections by adopting the FT-Star software in steps
Taking the determined basic parameters for simulation as input quantity, respectively carrying out simulation calculation on the rod-shaped sample models with the 5 different cross sections, taking the speed change criterion in the step (2.6.1.1) as a basis, changing the drawing speed when the calculated data meets the speed change criterion, continuously judging until the determined drawing speed does not meet the speed change criterion and the solidification is completely finished, wherein the determined drawing speed value is the maximum drawing speed value VmaxThereby establishing a series S of sectional area values corresponding to 5 sample models of the standard model series 10And a maximum drawing speed VmaxThe relationship pair of (1): [ S ]0(n)-Vmax(n)]，n＝1，2，3，4，5，
Step (2.6.1.2.3), according to the relation pair [ S ] of step (2.6.1.2.2)0(n)-Vmax(n)]Using BP neural network algorithm, with S0For input layer variables, with VmaxFor outputting layer variables, carrying out system training on the first group of standard examples according to the relation pair to obtain an inline relation between input quantity and output quantity, namely
F(S0)＝[Vmax]
Wherein, F (S)0) Shows the unified functional relationship determined by the BP neural network algorithm according to the 5 bar-shaped sample models of the first set of standard algorithms,
step (2.6.1.3) of determining a mutated section [ S [ ]1∶S2]And a maximum drawing speed vmaxAnd the functional relationship between the shift timing advance Δ t:
step (2.6.1.3.1) of creating a second set of 5 cross-section-mutated bar-like specimen models, which are recorded as a second set of standard calculation examples as a standard model series 2, [ S ]1∶S2]＝314.2∶706.9，314.2∶1256.6，314.2∶1963.5，706.9∶1963.5，1256.6∶2827.4，Unit: mm is2∶mm2All the bar-shaped sample models had a length of 300mm and a position z of the initial mutation of the cross section of 150mm,
S1the cross-sectional area value before cross-sectional change is represented by z1，
S2The cross-sectional area value after the cross-section change is shown as z along the z-direction coordinate2，
And satisfy, z1＜z＜z2，(z2-z1)/z＜5％，
Step (2.6.1.3.2), determining a maximum pull rate versus time curve for each bar model of the second set of standard calculations by:
step (2.6.1.3.2.1) of adopting the maximum speed formula F (S) of step (2.6.1.2.3)0)＝[Vmax]When the sectional area is changed, the drawing speed is correspondingly changed according to the functional relation,
and (2.6.1.3.2.2) determining the relation between the maximum drawing speed and time, and determining the time of the speed change point as t according to the set section starting mutation position z as 150mm1＝z/v1，t2＝z/v2Wherein
v1The area before the abrupt change of the cross section is S1The corresponding maximum drawing speed value is obtained,
v2the area is S after the section is suddenly changed2The corresponding maximum drawing speed value is obtained,
the drawing speed profile thus determined is given by v1Drawing at speed and duration t1Again, the velocity value is changed to start with v2Drawing at speed and duration t2，
And (2.6.1.3.3) according to the calculation simulation, correcting the variation relation of the maximum drawing speed of the second group of standard calculation examples along time: taking the curve of the maximum drawing speed determined in the step (2.6.1.3.2.3) along with the change of time as input, adopting the FT-Star software to carry out simulation calculation, and combining the speed change criterion to judge, when the speed change criterion is met, not changing the speed value, but reducing the speed change point time t1Is 0 per reduction5min, calculating again until the solidification is finished, accumulating all time reduction values, recording as delta t, and finally determining the corresponding relation pair of each model in the second group of standard calculation examples: [ S ]1(n)∶S2(n)-v1(n)∶v2(n)∶Δt(n)]，n＝1，2，3，4，5，
Step (2.6.1.3.4), according to the relation pair of step (2.6.1.3.3), adopting BP neural network algorithm, and using S1，S2As input layer variables, with v1，v2And delta t is an output layer variable, and the second standard example is subjected to system training to obtain an inline relation between input quantity and output quantity, namely
F(S1，S2)＝[v1，v2，Δt]
Wherein, F (S)1，S2) Shows the unified functional relationship determined by the BP neural network algorithm according to the 5 bar-shaped sample models of the second set of standard algorithms,
step (2.6.1.4), analyzing sectional area values of different sections according to the three-dimensional model of the actual blade shell, calculating a required drawing speed time-varying curve according to the sectional area, speed and time function relation determined in the step (2.6.1.3.4),
step (2.6.2), optimizing the solidification drawing speed curve v (t): taking the basic parameters for simulation determined in the step (2.5) as input, taking the three-dimensional discretization model established in the step (2.6.0) as input, taking the drawing speed variation curve with time established in the step (2.6.1) as input, adopting FT-Star software to perform simulation calculation, and adopting a speed change criterion to perform speed change judgment, wherein the speed change method when the criterion is met comprises the following steps:
the method comprises the following steps of automatically optimizing drawing speed, adjusting speed change quantity and speed change time point, determining the speed change quantity of each speed change according to a speed change rule, and dividing the speed change rule into two parts, namely a speed reduction rule and a speed increase rule:
a deceleration rule: z is a radical ofSL＜zid
a) When the deceleration criterion 1 is satisfied, the deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
Wherein,
Sk tand SMThe definition is shown in the step (2.6.1.1),
tprtthe time of the current coagulation,
tbfwhen the temperature value of the unit with the current mushy zone at the solidus line is reduced to the liquidus temperature from the casting starting temperature, the corresponding time point satisfies tbf＜tprt，
vmIs tbfThe speed value corresponding to the moment of time,
Lmthe speed is decreased by the adjustment factor,
b) when the deceleration criterion 2 is satisfied, the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: the program back-off time Δ t is 3min,
wherein,
zSLand zidThe definition is shown in the step (2.6.1.1),
vmis tbfThe speed value corresponding to the moment of time,
tbfwhen the temperature value of the unit with the current mushy zone at the solidus line is reduced to the liquidus temperature from the casting starting temperature, the corresponding time point satisfies tbf＜tprt，
c) When the deceleration criterion 3 is satisfied, Δ vm＝(1-Lm)vm，Lm＝10％；
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
d) When both the deceleration criterion 1 and the deceleration criterion 2 are fulfilled,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: amount of program backoff time Δ t1＝tprt-tbf，
Calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Let, Δ Vmin＝(ΔVm∶Δvm)，Δtmin＝(Δt1∶Δt2)，
Wherein,
ΔVminis Δ VmAnd Δ vmThe minimum value of the sum of the average values,
Δtminis Δ t1And Δ t2The minimum value of the sum of the average values,
when both the deceleration criterion 1 and the deceleration criterion 3 are fulfilled,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝10％；
Deceleration time position: time of program back-off Δ t ═ tprt-tbf，
Let, Δ Vmin＝(ΔVm∶Δvm)，
Wherein,
ΔVminis Δ VmAnd Δ vmThe minimum value of the sum of the average values,
when both the deceleration criterion 2 and the deceleration criterion 3 are fulfilled,
calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Calculating deceleration quantity delta v ″m＝(1-Lm)vm，Lm＝10％；
Deceleration time position: amount of program backoff time Δ t3＝tprt-tbf，
Let, Δ Vmin＝(Δvm∶Δv`m)，Δtmin＝(Δt2∶Δt3)，
Wherein,
ΔVminis Δ vmAnd Δ v ″mThe minimum value of the sum of the average values,
Δtminis Δ t2And Δ t3The minimum value of the sum of the average values,
when the deceleration criterion 1, the deceleration criterion 2 and the deceleration criterion 3 are simultaneously satisfied,
calculating deceleration quantity delta Vm＝(1-Lm)Vm，Lm＝(Sk t-SM)/SM
Deceleration time position: amount of program backoff time Δ t1＝tprt-tbf，
Calculating the deceleration amount Deltavm＝(1-Lm)vm，Lm＝(zSL-zid)/zid
Deceleration time position: amount of program backoff time Δ t2＝3min，
Calculating deceleration quantity delta v ″m＝(1-Lm)vm，Lm＝10％；
Deceleration time position: amount of program backoff time Δ t3＝tprt-tbf，
Let, Δ Vmin＝(ΔVm∶Δvm∶Δv`m)，Δtmin＝(Δt1∶Δt2∶Δt3)，
Wherein,
ΔVminis Δ Vm、ΔvmAnd Δ v ″mThe minimum value of the sum of the average values,
Δtminis Δ t1、Δt2And Δ t3The minimum value of the sum of the average values,
the amount of pull-out speed reduction is thus Δ VminThe deceleration time position is delta tmin，
B, speed increasing rule: when the criteria for acceleration are met,
acceleration amount Δ vp＝(1+Lp)vp，Lp＝(zSL-ziu)/ziu，
Speed-increasing time position: the current time is increased in speed,
wherein L ispThe speed is increased by the adjustment factor,
and (2.6.3) when the calculation result is verified to be passed according to the speed change criterion and the full-blade solidification is finished, drawing a curve according to the speed and the time to obtain a v (t) solidification drawing speed curve.
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