CN110376226B - Method for determining crack propagation characteristics of turbine engine rotor - Google Patents
Method for determining crack propagation characteristics of turbine engine rotor Download PDFInfo
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- CN110376226B CN110376226B CN201910595755.3A CN201910595755A CN110376226B CN 110376226 B CN110376226 B CN 110376226B CN 201910595755 A CN201910595755 A CN 201910595755A CN 110376226 B CN110376226 B CN 110376226B
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Abstract
The invention discloses a method for determining the crack propagation characteristics of a turbine engine rotor, which comprises the steps of defect manufacturing, structural member forging stock manufacturing, test block designing, test block manufacturing, rack orthogonal fatigue testing, full-focus phased array detection corresponding relation building, CT three-dimensional reconstruction detection corresponding relation building, test block fracture analysis, structural member manufacturing, structural member defect identification, structural member fatigue testing, structural member internal crack detection, structural member surface crack detection and structural member fracture analysis. The invention solves the problem of determining the positions and sizes of the defects and the cracks. The invention achieves the purpose of carrying out quantitative analysis on the internal characteristics of the internal cracks and the surface cracks, and achieves the purposes of mastering the crack propagation rule and further achieving the damage tolerance design. The related method has the characteristic of strong crack propagation characteristic determination capability, and overcomes the defects of the existing crack propagation characteristic determination technology.
Description
Technical Field
The invention belongs to the technical field of workpiece characteristic indication or measurement, and particularly relates to a method for determining crack propagation characteristics of a turbine engine rotor.
Background
Due to material, processing factors, there are certain sized defects (initial damage) in the structure. After the structure is in service for a period of time, cracks are easy to generate at the defect position, and the fatigue damage of the structure can be caused when the cracks expand to a certain size. Thus, the service life of the defect-containing structure is much less than the low cycle fatigue design life. For a turbine engine rotor structure with severe working conditions and high safety requirements, a damage tolerance design method is needed to analyze a crack propagation process in structural design and troubleshooting analysis, so that important parameter indexes such as reasonable overhaul interval time and the like are set. Damage tolerance design refers to a design methodology that assumes that a crack is present in a component, and that demonstrates with fracture mechanics, fatigue crack propagation analysis, and test verification that the crack does not propagate sufficiently to cause failure before it can be positively discovered under periodic inspection.
The defects are often buried in the structure, the crack propagation life of the formed crack after the crack propagates to the surface of the structure is short, and the crack propagation surface and internal characteristics need to be mastered. The existing method for determining the surface characteristics of surface crack propagation is mainly based on eddy current inspection, penetrant inspection and magnetic particle inspection, the precision can reach about 1 micron, and the method is well solved. The existing method for determining the internal crack propagation characteristics and the surface crack propagation internal characteristics is mainly based on ray method flaw detection and ultrasonic method flaw detection. The ultrasonic method can sensitively identify the defects and cracks, but the positions and the sizes of the defects and the cracks are difficult to determine due to the scattering and refraction effects of waves; the X-ray method can accurately position defects, but is not sensitive to non-open cracks and difficult to identify the cracks and the sizes of the cracks; the accuracy of the method for determining the internal crack propagation characteristics and the surface crack propagation internal characteristics can reach several millimeters, even more than dozens of millimeters, so that the problem still only remains on qualitative analysis. Aiming at the problem, the invention provides a crack propagation characteristic determination method, which is used for quantitatively determining the crack propagation characteristic and mastering the whole crack propagation rule so as to achieve the purpose of designing the damage tolerance.
Disclosure of Invention
In order to solve the problem that the existing method proposed in the technical background is not enough to achieve the purposes of determining the whole crack propagation characteristic, mastering the crack propagation rule and further achieving the damage tolerance design, the invention provides a method for determining the crack propagation characteristic of a turbine engine rotor.
In order to achieve the above object, the present invention provides the following technical solutions.
A method for determining crack propagation characteristics of a turbine engine rotor includes the steps of:
1) embedding defects in the structural member forging stock by adopting a prefabricating method; developing test block design through stress equivalence, strain equivalence and strain energy equivalence, and determining the size, the defect position and the tensile load value of the test block;
2) taking out test blocks containing different defects from the structural member forging stock; the test blocks containing different defects comprise series of test blocks containing defects with different set depths and defects with different set sizes;
3) developing a fatigue test of the test block, and detecting and identifying the defects and cracks of the test block by using full-focusing phased array detection and CT three-dimensional reconstruction under the specified cycle number; after the cracks are expanded to the surface, carrying out full-focusing phased array detection and CT three-dimensional reconstruction detection to identify the defects and the cracks of the test block under the specified cycle number, and simultaneously measuring the length of the surface cracks by using a fluorescence detection method and a surface replica method; after the test block is fractured, performing electron microscope scanning analysis and metallographic analysis on the fracture of the test block;
4) calibrating the sensitivity of the full-focus phased array detection and CT three-dimensional reconstruction detection method by combining the detection results of the defects and cracks of the test block and the fracture analysis result, establishing the corresponding relation between the test blocks with different defects and the detection results of the full-focus phased array, and establishing the corresponding relation between the test blocks with different defects and the CT three-dimensional reconstruction detection results;
5) machining the structural member forging stock to manufacture a structural member; carrying out a fatigue test on the structural part; carrying out full-focusing phased array detection and CT three-dimensional reconstruction detection; calibrating the positions and sizes of the defects and cracks in the structural part according to the corresponding relation established in the step 4) according to the detection result; the corresponding relation established in the step 4) comprises a complete crack propagation process of the test block, so that the crack propagation rule of the structural member can be obtained, the crack propagation life can be predicted, and the surface crack characteristic detection period of the structural member can be determined.
Preferably, in the step 5), when the crack approaches the surface, the surface size of the surface crack is measured, the internal characteristics of the surface crack are detected by applying the corresponding relation established in the step 4), the crack propagation characteristics can be further obtained, the crack propagation life of the structural member is predicted, and the surface characteristic detection period of the surface crack of the structural member is determined.
Preferably, the defects in the step 1) are cylindrical inclusions, the mechanical strength and the fatigue resistance of the cylindrical inclusions are weaker than those of structural member materials, and the defect burying positions are arranged at parts of the structural member which are easy to damage;
the method comprises the following steps of (1) embedding defects in a structural member forging blank by adopting a prefabricating method, wherein the prefabricating method comprises the following steps:
1.1) cutting the forging stock at a designated position;
1.2) digging a hole at a designated position of the cross section;
1.3) implanting cylindrical inclusions in the holes, and bonding the cut surfaces by hot isostatic pressing.
Preferably, in the step 2), the test blocks with different set depth defects are obtained by cutting the thickness of the test block; test blocks with different set size defects are obtained by prefabricating defects with different sizes in the step 1).
The invention has the beneficial effects that: the scheme of the invention solves the problem of determining the positions and sizes of the defects and the cracks by combining a standard block test, a structural part test, a full-focus phased array method, a CT three-dimensional reconstruction method and fracture analysis. The method achieves the purpose of quantitatively determining the internal characteristics of the internal cracks and the surface cracks, and achieves the purpose of mastering the crack propagation rule and further achieving the purpose of designing the damage tolerance. The related method has the characteristics of strong crack propagation characteristic determination capability and high precision, and overcomes the defects of the existing crack propagation characteristic determination technology.
Drawings
FIG. 1 is a flow chart of a method for determining crack propagation characteristics of a turbine engine rotor.
Fig. 2 is a schematic block diagram.
In the figure, 1, defects are preset, 2, bolt holes are clamped, X is the radial direction of a structural part, Y is the circumferential direction of the structural part, and Z is the axial direction of the structural part.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1, a method for determining a crack propagation characteristic of a turbine engine rotor specifically includes defect manufacturing, structural member forging stock manufacturing, test block designing, test block manufacturing, rack orthogonal fatigue testing, full-focus phased array detection correspondence building, CT three-dimensional reconstruction detection correspondence building, test block fracture analysis, structural member manufacturing, structural member defect identification, structural member fatigue testing, structural member internal crack detection, structural member surface crack detection, and structural member fracture analysis.
The defect constructed in the present invention is an inclusion with brittle properties and weak fatigue resistance, and is a series of sizes of cylinders (e.g., 0.5 x 0.5, 1.0 x 1.0, 1.5 x 1.5, 2 x 2). And burying the defects in the structural member forging stock, wherein the burying positions are provided with the interiors of key parts such as a structural member central hole, an eccentric hole, a mortise and the like, and the defects are uniformly distributed in the axial direction and the circumferential direction.
The preset method comprises the following steps: firstly, cutting a forging stock at a designated position; digging a hole at the designated position of the section; implanting inclusions in the holes, welding, and combining the cut surfaces through hot isostatic pressing.
The test block design means that the size, the defect position, the screw hole position and the tensile load value of the test block are determined through stress equivalence, strain equivalence and strain energy equivalence, so that the stress, strain and strain energy level and distribution of the preset defect position are consistent with those of a structural member, and the design is shown in figure 2. The test blocks are taken from the structural member forging stock and comprise a series of test blocks with defects of different depths and a series of test blocks with defects of different sizes. The test block with the defects of different depths is realized by cutting the thickness of the test block.
The bench orthogonal fatigue test refers to a low-cycle tensile fatigue test of a test block on a bench fatigue testing machine. In the test process, under different cycle numbers and different detection parameters, the defects of the test block are identified by using a full-focus phased array and CT three-dimensional reconstruction technology. And establishing a corresponding relation between the full-focusing phased array detection and the CT three-dimensional reconstruction detection by combining the fracture analysis result. And calibrating the internal crack characteristics by utilizing the corresponding relation when the structural member fatigue test is carried out. And when the crack develops to the surface, measuring the surface characteristics of the surface crack, and detecting the internal characteristics of the surface crack by using the corresponding relation. And after the structural fatigue test is finished, carrying out fracture analysis.
By combining a standard block test, a structural part test, a full-focusing phased array method, a CT three-dimensional reconstruction method and fracture analysis, the problem of determining the position and the size of the defect and the crack by the ultrasonic method is solved, and the purpose of determining the crack propagation characteristic is achieved.
In one particular application of the invention, the crack propagation characteristics are determined using the following procedure:
(1) determining the typical defect size of the structural part through statistical analysis of the fracture of the historical structural part; from the statistical analysis results, the defect sizes were determined, φ 0.5X 0.5, φ 1.0X 1.0, φ 1.5X 1.5, φ 2X 2.
(2) Determining a typical defect burying position of the structural part through statistical analysis of defect distribution of the historical structural part;
(3) embedding the specified defects into the specified positions of the forging stocks of the structural members by a preset method;
(4) by means of stress equivalence, strain equivalence and strain energy equivalence, test block design is developed, and the size, the defect position, the screw hole position and the tensile load value of the test block are determined.
(5) And (4) taking out the test block from the structural member forging stock according to the design parameters. The radial direction of the structural part is taken as the width direction (X axis) of the test block, the circumferential direction of the structural part is taken as the length direction (Y axis) of the test block, and the axial direction of the structural part is taken as the thickness direction (Z axis) of the test block.
(6) And carrying out fatigue test on the test block, and carrying out full-focusing phased array detection and CT three-dimensional reconstruction detection under the specified cycle number.
(7) After the crack propagates to the surface, full-focus phased array detection and CT three-dimensional reconstruction detection are performed at a specified number of cycles, and at the same time, the length of the surface crack is measured using fluorescence detection, surface replica method, or the like.
(8) And (4) after the test block is fractured, performing electron microscope scanning analysis, metallographic analysis and the like on the fracture of the test block.
(9) And calibrating the sensitivity of the full-focusing phased array detection and CT three-dimensional reconstruction method by combining the detection results of the defects and cracks of the test block and the fracture analysis results, and establishing a corresponding detection corresponding relation.
(10) And carrying out fatigue test on the structural member.
(11) And applying the detection corresponding relation to calibrate the positions and the sizes of the internal defects and the cracks.
(12) And when the crack approaches the surface, measuring the surface size of the surface crack, and measuring the internal size of the surface crack by applying the detection corresponding relation.
(13) And if the structural part is broken, carrying out fracture analysis, and further verifying and optimizing the detection corresponding relation.
(14) And if the structural member is not cracked, predicting the crack propagation life of the structural member.
(15) And (6) ending.
Through stress equivalence, strain equivalence and strain energy equivalence, the structural part and the test block have the same and similar defect characteristics and crack propagation characteristics. The test block is taken from the structural part, and the test block contains the part of the structural part which extends outwards from the vicinity of the defect preset position by a set distance (including the defect position) to the connecting end of the structural part and the shaft, and under the same detection mode and the similar fatigue test mode, the detection result of the structural part and the test block has a high equivalent relation.
The crack is obtained by the defect expansion, and the crack is expanded to the surface from the inside of the test block and the structural part along with the test, so that the test block and the structural part are finally fractured; the method for detecting the full-focusing phased array and the CT three-dimensional reconstruction can obtain the internal crack and surface crack detection characteristics of test blocks with different defects in the whole test process, and the crack propagation rule of the test blocks can be obtained through the crack characteristics of different test processes.
And during the fatigue test of the structural part, the test block with the same or close defect as the structural part can be obtained according to the established corresponding relation through the detection result of the fatigue test. According to the crack propagation rule of the test block, the crack propagation rule of the structural part can be obtained equivalently, and the current and initial defects and the positions and sizes of cracks of the structural part can be obtained. According to the crack propagation rule, the surface crack characteristic detection period of the structural part can be determined, or the purpose of damage tolerance design is achieved. The equivalent relation between the test blocks and the structural part allows certain errors, in the test process of the structural part, the crack propagation rule of the closest one or more test blocks can be found according to the detection result of the structural part, and for the condition of a plurality of test blocks, the crack propagation rule of the structural part can be obtained by means of an averaging method and the like according to the crack propagation rules of the plurality of test blocks. Of course, in order to be more precise, the set depth of the defect and the change gradient of the set size can be made as small as possible at the time of test block design without considering the test cost and the test time, so that a larger number of test blocks can be obtained to construct a more precise equivalence relation.
Claims (4)
1. A method for determining crack propagation characteristics of a turbine engine rotor, comprising the steps of:
1) embedding defects in a structural member forging stock by adopting a prefabricating method, developing test block design through stress equivalence, strain equivalence and strain energy equivalence, and determining the size, the position and the tensile load value of the test block;
2) taking out test blocks containing different defects from the structural member forging stock; the test blocks containing different defects comprise series of test blocks containing defects with different set depths and defects with different set sizes; the test block comprises a part of the structural member extending outwards from the vicinity of the defect preset position by a set distance to the connecting end of the structural member and the shaft;
3) developing a fatigue test of the test block, and detecting and identifying the defects and cracks of the test block by using full-focusing phased array detection and CT three-dimensional reconstruction under the specified cycle number; after the cracks are expanded to the surface, carrying out full-focusing phased array detection and CT three-dimensional reconstruction detection to identify the defects and the cracks of the test block under the specified cycle number, and simultaneously measuring the length of the surface cracks by using a fluorescence detection method and a surface replica method; after the test block is fractured, performing electron microscope scanning analysis and metallographic analysis on the fracture of the test block;
4) calibrating the sensitivity of the full-focus phased array detection and CT three-dimensional reconstruction detection method by combining the detection results of the defects and cracks of the test block and the fracture analysis result, establishing the corresponding relation between the test blocks with different defects and the detection results of the full-focus phased array, and establishing the corresponding relation between the test blocks with different defects and the CT three-dimensional reconstruction detection results;
5) machining the structural member forging stock to manufacture a structural member; carrying out a fatigue test on the structural part; carrying out full-focusing phased array detection and CT three-dimensional reconstruction detection; calibrating the positions and sizes of the defects and cracks in the structural part according to the corresponding relation established in the step 4) according to the detection result; the corresponding relation established in the step 4) comprises a complete crack propagation process of the test block, so that the crack propagation rule of the structural member can be obtained, the crack propagation life can be predicted, and the surface crack characteristic detection period of the structural member can be determined;
the step 5) is specifically as follows: during the fatigue test of the structural part, according to the detection result of the fatigue test, the corresponding relation between the test blocks with different defects and the detection result of the full-focus phased array established in the step 4) and the corresponding relation between the test blocks with different defects and the CT three-dimensional reconstruction detection result, the test block with the same or close to the defect of the structural part can be obtained; according to the crack propagation rule of the test block, the crack propagation rule of the structural part can be obtained equivalently, and the current and initial defects, the positions and the sizes of cracks of the structural part can be obtained; according to the crack propagation rule, the surface crack characteristic detection period of the structural part can be determined, or the purpose of damage tolerance design is achieved;
in the test process of the structural part, the crack propagation rule of the closest one or more test blocks is searched according to the detection result of the structural part, and for the condition of searching the crack propagation rules of the plurality of test blocks, the crack propagation rule of the structural part is obtained by adopting an averaging method according to the crack propagation rules of the plurality of test blocks.
2. The method for determining crack propagation characteristics of a turbine engine rotor as claimed in claim 1, wherein in step 5), the surface crack surface size is measured when the crack reaches the near surface, and the internal characteristics of the surface crack are detected by applying the correspondence established in step 4).
3. The method for determining crack propagation characteristics of a turbine engine rotor as claimed in claim 1, wherein the defect of step 1) is a cylindrical inclusion, the mechanical strength and fatigue resistance of the cylindrical inclusion are weaker than those of a structural material, and the defect burying position is arranged at a position where the structural material is easy to be damaged;
the method comprises the following steps of:
1.1) cutting the forging stock at a designated position;
1.2) digging a hole at a designated position of the cross section;
1.3) implanting cylindrical inclusions in the holes, and bonding the cut surfaces by hot isostatic pressing.
4. The method for determining the crack propagation characteristics of the turbine engine rotor as claimed in claim 1, wherein in the step 2), the test blocks with defects of different set depths are obtained by cutting the thickness of the test block; test blocks with different set size defects are obtained by prefabricating defects with different sizes in the step 1).
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| CN110967267A (en) * | 2019-11-25 | 2020-04-07 | 中国民用航空飞行学院 | Test method for judging fatigue crack initiation life |
| CN116773667B (en) * | 2023-06-15 | 2024-05-24 | 上海发电设备成套设计研究院有限责任公司 | Method and device for monitoring crack safety of rotor blade root groove of nuclear turbine |
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