CN112974734B - Manufacturing method of integrally formed swept combined blade - Google Patents
Manufacturing method of integrally formed swept combined blade Download PDFInfo
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- CN112974734B CN112974734B CN202110151751.3A CN202110151751A CN112974734B CN 112974734 B CN112974734 B CN 112974734B CN 202110151751 A CN202110151751 A CN 202110151751A CN 112974734 B CN112974734 B CN 112974734B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/26—Rotors specially for elastic fluids
- F04D29/32—Rotors specially for elastic fluids for axial flow pumps
- F04D29/38—Blades
- F04D29/384—Blades characterised by form
- F04D29/386—Skewed blades
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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Abstract
The invention provides a method for manufacturing an integrally formed swept combined blade, which adopts an investment casting method for manufacturing the integrally formed swept combined blade; designing and manufacturing a mould according to the shape of the integrally formed curved swept combined blade, and finally manufacturing the integrally formed curved swept combined blade through a series of steps of wax injection, sand pouring, dewaxing, mould shell roasting, casting, shell removal and heat treatment; compared with the traditional twisted forged blade, the safety is good, and the accuracy of the physical parameters of the blade is improved; the vortex noise is reduced, the pneumatic performance of the axial flow fan for the mine is improved, and the working efficiency of the axial flow fan for the mine is improved. Experiments prove that the full-pressure efficiency of the axial flow fan for the mine is 87%, and is improved by more than 5% compared with the full-pressure efficiency of the traditional axial flow fan for the mine.
Description
Technical Field
The invention belongs to the field of coal mine ventilation, relates to a swept-curved combined blade, and particularly relates to a manufacturing method of an integrally formed swept-curved combined blade.
Background
The mining fan is used as main technical equipment for mine safety production, is an important component of a mine ventilation system, and is the basis for mine safety production and disaster prevention and control. The problems of high and low operating efficiency and reliability of the mining fan are the focus of concern in coal mines. As the local old mine fan is aged and has low operating efficiency and is gradually replaced by the high-efficiency energy-saving fan, various fans are produced at the same time, and the counter-rotating fan is an updated product of the mine fan which is developed and produced by introducing a new technology of 80 years abroad after digestion and absorption. The coal mine air-conditioning system is deeply favored by coal mines due to the characteristics of high pressure, large flow, high efficiency, compact structure and easy air reversing. However, temporary practices prove that the counter-rotating axial flow mining fan has the defects of large noise and the like.
The energy consumption and noise of the ventilator are directly related to the core component of the ventilator, namely the fan blades, and the blade technology determines the final performance of the ventilator. Besides the torsion along the spanwise direction, the swept-curved blade has the inclination (curve) along the circumferential rotation direction and the inclination (sweep) along the incoming flow direction between the blade top and the blade root of the blade, and is a blade with a complex three-dimensional space structure. At present, the sweepback blades are widely applied to impeller machinery, and a large number of experimental researches and numerical calculations show that reasonable blade sweepback can change the radial component force of the acting force of the blades and airflow, control the pressure gradient distribution on the surfaces of the blades, reduce the flow loss and achieve the aim of improving the aerodynamic performance of the impeller machinery. The study on the swept blade mainly focuses on the sweep in the blade tip and blade root regions, but the study on the sweep in the whole blade height range, namely the specific shape of the barycentric stacking line is not discussed so much, and no consensus is made on the selection of the barycentric stacking line in any form and how to control the barycentric stacking line.
The traditional manufacturing method of the fan blade is manufactured by forging, pressing and twisting, and has the following defects: after high-temperature cooling, the blade is deformed, and the accuracy of the physical parameters of the blade and the stability of the operation of the blade are difficult to ensure.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a method for manufacturing an integrally formed curved and swept combined blade, and solves the technical problem that the aerodynamic performance of an axial flow fan during operation is not high due to low accuracy of physical parameters of the manufactured curved and swept combined blade in the prior art.
In order to solve the technical problems, the invention adopts the following technical scheme:
the manufacturing method of the integrally formed swept-curved combined blade adopts an investment casting method and is used for manufacturing the integrally formed swept-curved combined blade; designing and manufacturing a mould according to the shape of the integrally formed curved swept combined blade, and finally manufacturing the integrally formed curved swept combined blade through a series of steps of wax injection, sand pouring, dewaxing, mould shell roasting, casting, shell removal and heat treatment.
The invention also has the following technical characteristics:
the manufacturing method specifically comprises the following steps:
step one, designing and manufacturing a mould,
designing and manufacturing a mould according to the shape of the integrally formed swept combined blade, wherein the integrally formed swept combined blade comprises a blade handle and a blade body;
step two, wax is injected, and wax is injected into the mold cavity through the mold gate; after the wax in the mold cavity is solidified, demolding is finished to obtain a wax model of the swept-curved combined blade;
thirdly, spraying sand, namely uniformly coating the quartz sand and the adhesive on the surface of the integral blade wax model;
dewaxing, namely uniformly heating the quartz sand and the adhesive on the surface of the integral blade wax model after the quartz sand and the adhesive are hardened to obtain a hollow shell consisting of the quartz sand;
fifthly, roasting the mould shell, and heating the quartz sand mould shell at a high temperature to obtain a compact polycrystalline sintered body with a microstructure;
step six, casting, namely injecting molten metal liquid into the quartz sand cavity;
removing the shell, and removing the quartz sand shell to obtain the blade after the metal liquid is cooled;
and step eight, performing heat treatment, namely putting the blade obtained in the step eight into a high-temperature furnace, reheating to 100-150 ℃, keeping for 5-20 hours, and then cooling along with the furnace, so as to eliminate residual stress generated in casting.
The manufacturing method of the integrally formed swept combined blade designs and manufactures a mould according to the shape of the integrally formed swept combined blade, and the mould cavity comprises an integrally formed blade body cavity and a blade shank cavity; the blade body cavity comprises a blade body root cavity, a blade body middle cavity and a blade body top cavity; a petiole clamping groove cavity is formed in the petiole cavity, and a gravity center stacking line in the shape of the die cavity is a secondary Bezier curve;
the gravity center stacking line for controlling the shape of the blade cavity is projected in a circumferential plane to form a forward bending control line of the blade cavity, an x-y plane rectangular coordinate system is established in the circumferential plane, and x and y are respectively a horizontal coordinate and a vertical coordinate in the x-y plane rectangular coordinate system; in an x-y plane rectangular coordinate system, taking the intersection point of the gravity center of the blade root cavity and the blade shank cavity as the origin of coordinates, taking the tangential direction of the mold cavity as a horizontal coordinate x, and taking the radial direction of the mold cavity as a vertical coordinate y;
in an x-y plane rectangular coordinate system, the control equation of the forward bending control line of the blade cavity is as follows:
P x controlling the x-direction coordinate of a curve for controlling the forward bending of the blade cavity;
P y controlling the y-direction coordinate of the curve for forward bending of the blade body cavity sheet;
r is the radial length of the blade cavity;
alpha is a bending angle with the value range of 5-20 degrees;
t 1 for Bezier function arguments in a forward curve control line；
k x The control parameter of the forward curve control curve x direction of the blade body cavity is a value range of 0<k x <1.5；
k y The y-direction control parameter of the forward curve control curve of the blade cavity is a value range of 0<k y <1；
The gravity center stacking line for controlling the shape of the blade cavity is projected in an axial plane to form a forward bending control line of the blade cavity, a z-r plane rectangular coordinate system is established in the axial plane, and z and r are respectively a horizontal coordinate and a vertical coordinate in the z-r plane rectangular coordinate system; in a rectangular coordinate system of a z-r plane, taking the intersection point of the gravity center of a cavity at the root of the blade body and a cavity of the blade body of the petiole as a coordinate origin, taking the axial direction parallel to the cavity of the mold as a horizontal coordinate z, and taking the radial direction of the cavity of the mold as a vertical coordinate r;
in a rectangular coordinate system of a z-r plane, namely an axial plane, a forward-swept control line control equation of a blade cavity is as follows:
in the formula (I), the compound is shown in the specification,
P z a Z-direction coordinate of a forward-swept control curve of the blade cavity is obtained;
P r the forward sweep control curve r direction coordinate of the blade body cavity is shown;
r is the radial length of the blade cavity;
beta is a sweep angle, and the value range is 5-15 degrees;
t 2 is a Bezier function independent variable in a forward sweep control line;
k z a control parameter in the Z direction of a forward-swept control curve of the blade cavity is obtained, and the value range is-1<k z <1；
k r The forward sweep control curve r direction control parameter of the blade body cavity is a value range of 0<k r <1。
Compared with the prior art, the invention has the following technical effects:
the method adopts an investment casting method to integrally form, and then carries out artificial aging treatment to eliminate residual stress generated by casting, so that the method has better safety compared with the traditional twisted forged blade, and improves the accuracy of physical parameters of the blade.
The gravity center stacking line for controlling the blade body shape of the curved and swept combined blade is the curved and swept combined blade with the secondary Bezier curve, so that the radial force gradient of the blade and the secondary flow distribution along the blade height are effectively controlled, the boundary layer stacking is eliminated, the vortex convergence is avoided, the vortex noise is reduced, the pneumatic performance of the mining axial flow fan is improved, and the working efficiency of the mining axial flow fan is improved. Experiments prove that the full-pressure efficiency of the axial flow fan for the mine is 87%, and is improved by more than 5% compared with the full-pressure efficiency of the traditional axial flow fan for the mine.
(III) the blade adopts the integrally formed swept combined blade, the swept combined orthogonal three-dimensional optimization design theory design is applied, the cross section of the blade is in a wing shape, and the front edge of the blade is designed with a fillet, so that the reduction of the fatigue resistance of the blade caused by the sharp blade top is avoided, the strength and the rigidity of the blade are improved, and the service life of the blade is prolonged.
(IV) the blades of the swept combined blade are swept forward by 15 degrees, so that the static pressure distribution of the suction surface at the tip of the movable blade can be adjusted, the pressure difference between the pressure surface and the tip of the movable blade is reduced, and the loss caused by tip leakage vortex is reduced; by changing the static pressure distribution of the suction surface, the static pressure gradient pointing to the blade tip from the blade is reduced, the radial secondary flow on the surface of the blade is weakened, the accumulation of low-energy fluid on the blade tip is avoided, and the pneumatic performance and efficiency of the blade are improved.
(V) the forward bending of the blades of the swept-curved combined blade changes the static pressure distribution at the lower end wall of the blade, reduces the suction surface counter pressure gradient of the blade root, weakens the loss caused by circumferential secondary flow at the end wall of the blade root, enables the low-energy fluid at the root of the movable blade to migrate to the middle of the blade in advance, reduces the loss and airflow blockage caused by the accumulation of the low-energy fluid at the tail edge of the blade root, and improves the pneumatic performance and efficiency of the blade.
Drawings
Fig. 1 is a schematic view of an impeller structure.
Fig. 2 is a schematic view of a blade structure.
FIG. 3 is a schematic top view of a blade.
Fig. 4 is a schematic view of a clamp structure.
FIG. 5 is a grid division diagram of stress concentration sites of the hub and key positions of the blade.
Fig. 6 is a cloud of radial deformations of the impeller.
FIG. 7 is a curve diagram of the x-y plane forward curvature of a swept combined blade.
FIG. 8 is a z-r plane forward sweep graph of a curved swept combined blade.
Fig. 9 is a schematic structural diagram of a mining axial-flow fan.
FIG. 10 is a full streamline distribution diagram of a mining axial-flow fan under a working condition of 2500Pa static pressure rise.
FIG. 11 is a full streamline distribution diagram of a mining axial-flow fan under a static pressure rise working condition of 3000 Pa.
The meaning of the individual reference symbols in the figures is: 1-blade body, 2-blade stalk, 3-blade stalk clamping groove and 4-sweepback combined blade. 5-hub, 6-impeller, 7-hub rotating shaft mounting disc, 8-hub rotating shaft mounting hole, 9-annular web, 10-blade mounting groove, 11-blade mounting disc, 12-blade mounting hole, 13-pin-shaped notch, 14-hoop, 15-wind barrel, 16-motor, 17-first-stage motor barrel, 18-second-stage motor barrel, 19-conical transition section motor barrel and 20-rib plate.
101-blade root, 102-blade middle, 103-blade top, 104-blade leading edge, and 105-blade trailing edge.
601-first-stage impeller, 602-second-stage impeller.
1401-first sub-band, 1402-second sub-band, 1403-bolt, 1404-pin boss.
1501-air inlet cylinder, 1502-air outlet cylinder.
1601-first-stage motor, 1602-second-stage motor.
The present invention will be explained in further detail with reference to examples.
Detailed Description
A manufacturing method of an integrally formed swept-curved combined blade is characterized in that a gravity center stacking line of a mold cavity shape is a quadratic Bezier curve; the gravity center stacking line for controlling the shape of the mold cavity of the curved and swept combined blade is projected in a circumferential plane to form a blade body cavity forward-bending control line, the gravity center stacking line for controlling the shape of the mold cavity of the curved and swept combined blade is projected in an axial plane to form a blade body cavity forward-sweeping control line, an x-y plane rectangular coordinate system is established in the circumferential plane, and x and y are respectively a horizontal coordinate and a vertical coordinate in the x-y plane rectangular coordinate system; in an x-y plane rectangular coordinate system, taking the intersection point of the gravity center of the blade root cavity and the blade shank cavity as the origin of coordinates, taking the tangential direction of the mold cavity as a horizontal coordinate x, and taking the radial direction of the mold cavity as a vertical coordinate y; the gravity center stacking line for controlling the shape of the blade body cavity is projected in an axial plane to form a blade forward bending control line, a z-r plane rectangular coordinate system is established in the axial plane, and z and r are respectively an abscissa and an ordinate in the z-r plane rectangular coordinate system; in a rectangular coordinate system of a z-r plane, the intersection point of the gravity center of a cavity at the root of the blade body and a cavity of the blade body of the petiole is taken as an origin of coordinates, the axial direction parallel to the cavity of the mold is taken as a horizontal coordinate z, and the radial direction of the cavity of the mold is taken as a vertical coordinate r.
The center of gravity stacking line, the circumferential plane and the axial plane are common knowledge in the art.
The center of gravity stacking line is defined as a curve formed by the root of the blade body root cavity of the blade to the center of gravity of each section of the blade body top cavity.
The circumferential plane is defined as a circumferential plane formed by the circumferential tangent of the impeller and the radial direction of the impeller, namely a plane which is perpendicular to the rotating central axis of the impeller and divides the thickness of the impeller.
The axial plane is defined as the axial plane formed by the axial direction of the impeller and the radial direction of the impeller, namely the plane which is parallel to the rotation central axis of the impeller and bisects the impeller.
As shown in FIGS. 7 and 8, the barycentric stacking line of the mold cavity shape is a quadratic Bezier curve, and the starting point P of the barycentric stacking line 1 Is the intersection point of the blade root cavity center of gravity and the blade shank, namely a starting point P 1 The origin of coordinates on a rectangular coordinate system of an x-y plane, the point a is a cavity in the middle of the blade body, and the point P is 2 Is the center of gravity of the cavity at the top of the blade body, P 3 Is a forward curve control point, k, of the blade cavity x For the forward curve control point P of the blade cavity 3 Control parameter in the x-direction, k y For the forward curve control point P of the blade cavity 3 A control parameter in the y-direction; p is 4 Is a forward sweep control point, k, of the blade cavity z For the forward sweep control point P of the blade cavity 4 Control parameter in z-direction, k r For the forward sweep control point P of the blade 4 Control parameters in the r direction. Introducing specific parameters of the blade: blade length R, bend angle alpha, sweep angle beta.
Under the rectangular coordinate system of the x-y plane, the blade cavity is bent forward at each point P 1 、P 2 、P 3 The coordinates of (a) are: p is 1 (0，0)、P 2 (R sinα、R cosα)、P 3 (k x R sinα、k y R cos α); under a rectangular coordinate system of a z-r plane, forward-swept points P of the blade cavity 1 、P 2 、P 4 The coordinates of (a) are: p 1 (0，0)、P 2 (R sinβ、R cosβ)、P 4 (k z R sinβ、k z R cosβ)。
In an x-y plane rectangular coordinate system, the control equation of the forward bending control line of the blade cavity is as follows:
in a rectangular coordinate system of a z-r plane, the forward-swept control line control equation of the blade cavity is as follows:
in the formula (I), the compound is shown in the specification,
P x controlling the x-direction coordinate of a curve for controlling the forward bending of the blade cavity;
P y controlling the y-direction coordinate of the curve for forward bending of the blade cavity;
P z a Z-direction coordinate of a forward-swept control curve of the blade cavity is obtained;
P r the forward sweep control curve r direction coordinate of the blade body cavity is shown;
r is the radial length of the blade cavity;
alpha is a bending angle with the value range of 5-20 degrees;
beta is a sweep angle, and the value range is 5-15 degrees;
t 1 is a Bezier function independent variable in a forward control line;
t 2 is a Bezier function independent variable in a forward sweep control line;
k x the control parameter of the forward curve control curve x direction of the blade body cavity is a value range of 0<k x <1.5；
k y The y-direction control parameter of the forward curve control curve of the blade cavity is a value range of 0<k y <1；
k z A control parameter in the Z direction of a forward-swept control curve of the blade cavity is obtained, and the value range is-1<k z <1；
k r The forward sweep control curve r direction control parameter of the blade body cavity is a value range of 0<k r <1。
All parts in the present invention are those known in the art, unless otherwise specified.
The following embodiments of the present invention are provided, and it should be noted that the present invention is not limited to the following embodiments, and all equivalent changes based on the technical solutions of the present invention are within the protection scope of the present invention.
Example 1:
the embodiment provides a manufacturing method of an integrally formed swept-curved combined blade, which adopts an investment casting method for manufacturing the integrally formed swept-curved combined blade; designing and manufacturing a mould according to the shape of the integrally formed curved swept combined blade, and finally manufacturing the integrally formed curved swept combined blade through a series of steps of wax injection, sand pouring, dewaxing, mould shell roasting, casting, shell removal and heat treatment.
As a preferable aspect of this embodiment, the manufacturing method specifically includes the following steps:
step one, designing and manufacturing a mould,
designing and manufacturing a mould according to the shape of the integrally formed swept combined blade, wherein the integrally formed swept combined blade comprises a blade handle and a blade body;
step two, wax is injected, and wax is injected into the mold cavity through the mold gate; after the wax in the mold cavity is solidified, demolding is finished to obtain a wax model of the swept-curved combined blade;
thirdly, spraying sand, namely uniformly coating the quartz sand and the adhesive on the surface of the integral blade wax model;
dewaxing, namely uniformly heating the quartz sand and the adhesive on the surface of the integral blade wax model after hardening to obtain an empty shell consisting of the quartz sand; in the embodiment, the adhesive is alkaline silica sol;
fifthly, roasting the mould shell, heating the quartz sand mould shell at high temperature, connecting solid particles with each other, growing crystal grains, gradually reducing gaps and crystal boundaries, and increasing the density through the transfer of substances to obtain a compact polycrystalline sintered body with a microstructure; in the embodiment, the high temperature is mainly limited to 900-1100 ℃;
step six, casting, namely injecting molten metal liquid into the quartz sand cavity;
removing the shell, and removing the quartz sand shell to obtain the blade after the metal liquid is cooled;
step eight, heat treatment, namely putting the blade obtained in the step eight into a high-temperature furnace to be reheated to 100-150 ℃, keeping the temperature for 5-20 hours and then cooling the blade along with the furnace, so as to eliminate residual stress generated in casting.
As a preferable solution of this embodiment, the manufacturing method of the integrally formed swept-curved composite blade adopts an investment casting method for manufacturing the integrally formed swept-curved composite blade; designing and manufacturing a mould according to the shape of the integrally formed curved and swept combined blade, wherein the mould cavity comprises an integrally formed blade body cavity and a blade shank cavity; the blade body cavity comprises a blade body root cavity, a blade body middle cavity and a blade body top cavity; a petiole clamping groove cavity is formed in the petiole cavity, and a gravity center stacking line in the shape of the die cavity is a secondary Bezier curve;
the gravity center stacking line for controlling the shape of the blade cavity is projected in a circumferential plane to form a forward bending control line of the blade cavity, an x-y plane rectangular coordinate system is established in the circumferential plane, and x and y are respectively a horizontal coordinate and a vertical coordinate in the x-y plane rectangular coordinate system; in an x-y plane rectangular coordinate system, taking the intersection point of the gravity center of a cavity at the root part of a blade body and a cavity of a blade shank as an origin of coordinates, taking the tangential direction of the mold cavity as a horizontal coordinate x, and taking the radial direction of the mold cavity as a vertical coordinate y;
in an x-y plane rectangular coordinate system, the control equation of the forward bending control line of the blade cavity is as follows:
P x controlling the x-direction coordinate of a curve for controlling the forward bending of the blade cavity;
P y the y-direction coordinate of the forward bending control curve of the blade body cavity sheet is shown;
r is the radial length of the blade cavity;
alpha is a bending angle with the value range of 5-20 degrees;
t 1 is a Bezier function independent variable in a forward control line;
k x the control parameter of the forward curve control curve x direction of the blade body cavity is a value range of 0<k x <1.5；
k y The y-direction control parameter of the forward curve control curve of the blade cavity is set to be 0<k y <1；
The gravity center stacking line for controlling the shape of the blade cavity is projected in an axial plane to form a forward bending control line of the blade cavity, a z-r plane rectangular coordinate system is established in the axial plane, and z and r are respectively a horizontal coordinate and a vertical coordinate in the z-r plane rectangular coordinate system; in a rectangular coordinate system of a z-r plane, taking the intersection point of the gravity center of a cavity at the root of the blade body and a cavity of the blade body of the petiole as a coordinate origin, taking the axial direction parallel to the cavity of the mold as a horizontal coordinate z, and taking the radial direction of the cavity of the mold as a vertical coordinate r;
in a rectangular coordinate system of a z-r plane, namely an axial plane, a forward-swept control line control equation of a blade cavity is as follows:
in the formula (I), the compound is shown in the specification,
P z a Z-direction coordinate of a forward-swept control curve of the blade cavity is obtained;
P r the forward sweep control curve r direction coordinate of the blade body cavity is shown;
r is the radial length of the blade cavity;
beta is a sweep angle, and the value range is 5-15 degrees;
t 2 is a Bezier function independent variable in a forward sweep control line;
k z a Z-direction control parameter of a forward-swept control curve of a blade cavity is obtained, and the value range is-1<k z <1；
k r The forward sweep control curve r direction control parameter of the blade body cavity is a value range of 0<k r <1。
As a preferable scheme of this embodiment, the thickness of the mold cavity gradually decreases from the front edge to the rear edge.
Example 2:
this embodiment provides an integrally formed swept-curved composite blade, which is manufactured according to the manufacturing method described in embodiment 1, and the mold cavity described in embodiment 1 is matched with the integrally formed swept-curved composite blade in this embodiment; comprises an integrally formed blade body 1 and a blade handle 2; the blade body 1 comprises a blade body root 101, a blade body middle part 102 and a blade body top part 103; a petiole clamping groove 3 is formed in the petiole 2, and a gravity center stacking line of the shape of the blade body 1 of the sweep-controlling combined blade 4 is a quadratic Bezier curve; wherein the content of the first and second substances,
the gravity center stacking line for controlling the shape of the blade body 1 of the sweep combined blade 4 is projected in a circumferential plane to form a blade forward-bending control line, an x-y plane rectangular coordinate system is established in the circumferential plane, and x and y are respectively a horizontal coordinate and a vertical coordinate in the x-y plane rectangular coordinate system; in an x-y plane rectangular coordinate system, taking the intersection point of the gravity center of the root of the blade body and the blade shank as a coordinate origin, taking the tangential direction of an impeller where the blade is located as a horizontal coordinate x, and taking the radial direction of the blade as a vertical coordinate y; in an x-y plane rectangular coordinate system, a blade forward-bending control line control equation is as follows:
P x controlling the x-direction coordinate of the curve for the forward bending of the blade;
P y a y-direction coordinate of a blade forward bending control curve;
r is the radial length of the blade;
alpha is a bending angle, and the value range is 5-20 degrees;
t 1 is a Bezier function independent variable in a forward control line;
k x the control parameter of the forward curve of the blade in the x direction is a value range of 0<k x <1.5；
k y The value range of the y-direction control parameter of the blade forward bending control curve is 0<k y <1；
The gravity center integral line for controlling the shape of the blade body 1 of the sweep combined blade 4 is projected in an axial plane to form a blade forward-bending control line, a z-r plane rectangular coordinate system is established in the axial plane, and z and r are respectively an abscissa and an ordinate in the z-r plane rectangular coordinate system; in a rectangular coordinate system of a z-r plane, taking the intersection point of the gravity center of the root of the blade body and the blade handle as a coordinate origin, taking the axial direction of the rotation center of the impeller in which the blade is parallel to as a horizontal coordinate z, and taking the radial direction of the blade as a vertical coordinate r; in a rectangular coordinate system of a z-r plane, namely an axial plane, a control equation of a forward-swept control line of the blade is as follows:
in the formula (I), the compound is shown in the specification,
P z a Z-direction coordinate of a forward-swept control curve of the blade;
P r the direction coordinate of the forward-swept control curve r of the blade is shown;
r is the radial length of the blade;
beta is a sweep angle, and the value range is 5-15 degrees;
t 2 is a Bezier function independent variable in a forward sweep control line;
k z the value range of the Z-direction control parameter of the forward-swept control curve of the blade is-1<k z <1；
k r The forward sweep control curve r direction control parameter of the blade is a value range of 0<k r <1。
As a preferable mode of the present embodiment, for the sweep-down combination vane 4 having a vane length of 532mm,
the three parameters of the control equation of the forward bending control line of the blade are as follows:
α＝10°；
k x ＝1.4；
k y ＝0.6；
the three parameters of the control equation of the forward-swept control line of the blade are as follows:
β＝15°；
k z ＝-0.6；
k r ＝0.8。
as a preferable solution of this embodiment, the blade body middle part 102 of the swept-blade assembly 4 is at 0.4 of the blade body.
As a preferable solution of this embodiment, the swept-curved composite blade 4 is specifically an integrally formed aluminum alloy swept-curved composite blade.
As a preferable solution of this embodiment, the thickness of the blade body 1 of the swept-curved combined blade 4 gradually decreases from the blade body leading edge 104 to the blade body trailing edge 105.
An impeller is characterized in that a plurality of curved and swept combined blades 4 are uniformly arranged along the circumferential direction of a hub 5 to form an impeller 6, a hub rotating shaft mounting disc 7 protruding forwards and backwards is arranged at the center of the hub 5, a hub rotating shaft mounting hole 8 is formed in the center of the hub rotating shaft mounting disc 7, an annular web 9 is arranged on the end face of the hub rotating shaft mounting disc 7, and uniformly distributed blade mounting grooves 10 are formed in the annular web 9; the outer circle of the annular web plate 9 is provided with a blade mounting disc 11 protruding from the front and the back, the blade mounting disc 11 is provided with a blade mounting hole 12 which runs through the blade mounting disc 11 and corresponds to the blade mounting groove 10 towards the center of the hub 5, and the blade mounting hole 12 is provided with a pin-shaped notch 13.
As a preferable scheme of this embodiment, the swept-curved combined blade 4 is fixedly installed in the blade mounting hole 12 through a hoop 14, the hoop 14 includes a first sub-hoop 1401 and a second sub-hoop 1402, the first sub-hoop 1401 and the second sub-hoop 1402 are connected through a bolt 1403, and an end face of the first sub-hoop 1401 is provided with a pin-shaped boss 1404.
An axial-flow fan comprises an air duct 15, a motor 16 and an impeller 6, wherein the air duct 15 comprises an air inlet duct 1501 and an air outlet duct 1502, the motor 16 comprises a primary motor 1601 and a secondary motor 1602, and the impeller 6 comprises a primary impeller 601 and a secondary impeller 602; the first-stage impeller 601 is connected with the first-stage motor 1601, the first-stage motor 1601 is installed in the first-stage motor barrel 17, and the first-stage motor barrel 17 is installed in the air inlet barrel 1501; the secondary impeller 602 is connected with a secondary motor 1602, the secondary motor 1602 is installed in a secondary motor barrel 18, and the secondary motor barrel 18 is installed in the air outlet barrel 1502; the secondary motor barrel 18 is arranged to be connected to the conical transition section motor barrel 19, the primary impeller 601 and the secondary impeller 602 are impellers as claimed in claim 7, and the primary impeller 601 and the secondary impeller 602 are oppositely arranged to rotate in opposite directions.
As a preferable scheme of this embodiment, the number of the blades of the primary impeller 601 is 10, and the number of the blades of the secondary impeller 602 is 9.
As a preferable solution of this embodiment, the hub rotating shaft mounting holes 8 at the centers of the hubs 5 of the primary impeller 601 and the secondary impeller 602 are rotatably mounted on the primary motor 1601 and the secondary motor 1602 respectively; the primary motor 1601 and the secondary motor 1602 are explosion-proof motors, and the primary motor barrel 17 and the secondary motor barrel 18 are connected with the air duct 15 through a rib plate 20.
As shown in fig. 5, finite element meshing is performed on the impeller, and in order to obtain a good calculation result, the mesh is subjected to encryption division at a key part of stress and a stress concentration part. Finite element strength analysis of the impeller as shown in fig. 6, the maximum radial displacement occurred at the leading edge of the tip of the blade body, which was 0.38999mm. The value of the top clearance is far smaller than the top clearance standard of the blade body of the ventilator, which is specified by national coal safety regulations and is larger than 3mm.
According to the technical scheme, as shown in fig. 9, the distance between the first-stage impeller and the second-stage impeller is 30mm, and the clearance between the swept-curved combined blades mounted on the first-stage impeller and the second-stage impeller and the air duct is 3mm.
The flow analysis is carried out on the mining axial-flow fan, the numerical simulation of the mining axial-flow fan is carried out under the standard atmospheric condition, the flowing medium is air, the atmospheric pressure PA =101325Pa, the ambient temperature TA =25 ℃, the gas density rho =1.185kg/m & lt 3 & gt, the altitude A =0m, and the rotating speed n =590rpm of the simulated fan.
As shown in fig. 10 and 11, in the steady-state flow numerical simulation of the ventilator, each blade channel is periodically symmetrical, so that the flow of only one periodic channel needs to be calculated. Along with the increase of back pressure, the forward swirling speed of the airflow at the outlet of the second-stage impeller is increased, obvious airflow separation phenomena do not occur in the straight blade channel and the motor cylinder at the conical transition section, but an airflow three-dimensional separation backflow area occurs in the motor cylinder at the conical transition section of the mining axial flow fan. This is because the fan tail cone has an insufficient model length, but there is no sign of separation, stall, in the vane passages and the spar ring section passages.
CFD analysis is a technique commonly used in the art. The static pressure refers to the pressure of the air on the surface of an object parallel to the airflow, the static pressure of the ventilator is used for overcoming the resistance of an air supply pipeline, and the size of the static pressure determines the air supply quantity of the ventilator.
Compared with the existing mining axial-flow fan, the pneumatic noise caused by the blades is measured and tested under the condition that the silencer is not additionally arranged. Table 1 and table 2 show the sound pressure level test results of the integrally formed curved and swept combined blade axial flow fan for mine and the conventional axial flow fan for mine respectively:
TABLE 1 integrally formed axial-flow ventilator for mine with curved and swept combined blades (dB)
TABLE 2 Sound pressure level data (dB) of traditional axial-flow ventilator for mine
The above test comparison can be obtained, and under the condition that no silencer is additionally arranged, the noise of the traditional mining axial flow fan with the integrally formed bent and swept combined blades is obviously reduced by about 10 decibels compared with the noise of the traditional mining axial flow fan with the traditional blades.
Claims (3)
1. The manufacturing method of the integrally formed swept-curved combined blade is characterized in that the manufacturing method of the integrally formed swept-curved combined blade adopts an investment casting method and is used for manufacturing the integrally formed swept-curved combined blade; designing and manufacturing a mould according to the shape of the integrally formed curved swept combined blade, and finally manufacturing the integrally formed curved swept combined blade through a series of steps of wax injection, sand pouring, dewaxing, mould shell roasting, casting, shell removal and heat treatment;
designing and manufacturing a mould according to the shape of the integrally formed bent and swept combined blade, wherein the mould cavity comprises an integrally formed blade body cavity and a blade shank cavity; the blade body cavity comprises a blade body root cavity, a blade body middle cavity and a blade body top cavity; a petiole clamping groove cavity is formed in the petiole cavity, and a gravity center stacking line in the shape of the die cavity is a secondary Bezier curve;
the gravity center stacking line for controlling the shape of the blade cavity is projected in a circumferential plane to form a forward bending control line of the blade cavity, an x-y plane rectangular coordinate system is established in the circumferential plane, and x and y are respectively a horizontal coordinate and a vertical coordinate in the x-y plane rectangular coordinate system; in an x-y plane rectangular coordinate system, taking the intersection point of the gravity center of the blade root cavity and the blade shank cavity as the origin of coordinates, taking the tangential direction of the mold cavity as a horizontal coordinate x, and taking the radial direction of the mold cavity as a vertical coordinate y;
in an x-y plane rectangular coordinate system, the control equation of the forward bending control line of the blade cavity is as follows:
P x controlling the x-direction coordinate of a curve for controlling the forward bending of the blade cavity;
P y controlling the y-direction coordinate of the curve for forward bending of the blade body cavity sheet;
r is the radial length of the blade cavity;
alpha is a bending angle, and the value range is 5-20 degrees;
t 1 is a Bezier function independent variable in a forward control line;
k x controlling parameters of a forward curve control curve x direction of a blade cavity in a value range of 0<k x <1.5；
k y The y-direction control parameter of the forward curve control curve of the blade cavity is a value range of 0<k y <1；
The gravity center stacking line for controlling the shape of the blade cavity is projected in an axial plane to form a forward bending control line of the blade cavity, a z-r plane rectangular coordinate system is established in the axial plane, and z and r are respectively a horizontal coordinate and a vertical coordinate in the z-r plane rectangular coordinate system; in a rectangular coordinate system of a z-r plane, taking the intersection point of the gravity center of a cavity at the root of the blade body and a cavity of the blade body of the petiole as a coordinate origin, taking the axial direction parallel to the cavity of the mold as a horizontal coordinate z, and taking the radial direction of the cavity of the mold as a vertical coordinate r;
in a rectangular coordinate system of a z-r plane, namely an axial plane, a forward-swept control line control equation of a blade cavity is as follows:
in the formula (I), the compound is shown in the specification,
P z a Z-direction coordinate of a forward-swept control curve of the blade cavity is obtained;
P r the forward sweep control curve r direction coordinate of the blade body cavity is shown;
r is the radial length of the blade cavity;
beta is a sweep angle, and the value range is 5-15 degrees;
t 2 is a Bezier function independent variable in a forward sweep control line;
k z a control parameter in the Z direction of a forward-swept control curve of the blade cavity is obtained, and the value range is-1<k z <1；
k r The forward sweep control curve r direction control parameter of the blade body cavity is a value range of 0<k r <1。
2. The method of manufacturing an integrally formed swept composite blade according to claim 1, wherein the method specifically comprises the steps of:
step one, designing and manufacturing a mould,
designing and manufacturing a mould according to the shape of the integrally formed swept combined blade, wherein the integrally formed swept combined blade comprises a blade handle and a blade body;
step two, wax is injected, and the wax is injected into the mold cavity through a mold gate; after the wax in the mold cavity is solidified, demolding is finished to obtain a wax model of the sweepback combined blade;
thirdly, spraying sand, namely uniformly coating the quartz sand and the adhesive on the surface of the integral blade wax model;
dewaxing, namely uniformly heating the quartz sand and the adhesive on the surface of the integral blade wax model after hardening to obtain an empty shell consisting of the quartz sand;
fifthly, roasting the mould shell, and heating the quartz sand mould shell at a high temperature to obtain a compact polycrystalline sintered body with a microstructure;
step six, casting, namely injecting molten metal liquid into the quartz sand cavity;
removing the shell, namely removing the quartz sand shell to obtain the blade after the metal liquid is cooled;
and step eight, performing heat treatment, namely putting the blade obtained in the step eight into a high-temperature furnace, reheating to 100-150 ℃, keeping for 5-20 hours, and then cooling along with the furnace, so as to eliminate residual stress generated in casting.
3. The method of manufacturing an integrally formed swept composite blade of claim 1, wherein the mold cavity has a thickness that gradually decreases from the leading edge to the trailing edge.
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| CN107237777A (en) * | 2017-08-01 | 2017-10-10 | 中国农业大学 | A kind of agricultural ventilation blower flexural tensile elastic modulus and its design method |
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| CN101235827A (en) * | 2008-03-03 | 2008-08-06 | 刘建国 | Blower fan integral wheel and method of manufacture |
| CN107237777A (en) * | 2017-08-01 | 2017-10-10 | 中国农业大学 | A kind of agricultural ventilation blower flexural tensile elastic modulus and its design method |
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