CN113378315A - Method for preventing turbine crack initiation - Google Patents
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- CN113378315A CN113378315A CN202110670159.4A CN202110670159A CN113378315A CN 113378315 A CN113378315 A CN 113378315A CN 202110670159 A CN202110670159 A CN 202110670159A CN 113378315 A CN113378315 A CN 113378315A
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- 239000000463 material Substances 0.000 description 9
- 238000002485 combustion reaction Methods 0.000 description 8
- 229910045601 alloy Inorganic materials 0.000 description 4
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- 238000010586 diagram Methods 0.000 description 4
- 239000000446 fuel Substances 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 230000003068 static effect Effects 0.000 description 3
- 230000008646 thermal stress Effects 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
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- 238000011161 development Methods 0.000 description 1
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Abstract
The invention discloses a method for preventing turbine cracks from generating, which comprises the following steps: simulating and calculating the stress distribution of the single-sector turbine based on the analysis model of the turbine; based on the result of the stress distribution, carrying out structural optimization on an analysis model of the turbine to reduce local stress under the condition that the stress of the turbine structure is determined to exceed the maximum allowable stress; judging the rationality of structure optimization; and responding to the determined structural optimization reasonableness, and performing structural optimization on the turbine based on the spline curve determined by the structural optimization. The stress distribution of the single-sector turbine is calculated by adopting a finite element method, and the method comprises the following steps: setting stress distribution calculation conditions to divide grids; establishing a finite element model and judging the convergence of the grids; and performing stress analysis under the condition that the calculation result of the finite element model is determined to pass the grid convergence test. The stress distribution of the single-sector turbine is calculated by adopting a finite element method, and the structure of an analysis model of the turbine is optimized, so that cracks can be prevented from being generated in the use stage of the turbine.
Description
Technical Field
The invention relates to a method for preventing turbine cracks from being initiated, and belongs to the technical field of turbines of micro-combustion engines.
Background
The micro-combustion engine uses continuously flowing gas as working medium to drive the impeller to rotate at high speed, and converts the energy of fuel into useful work, and is a rotary impeller type heat engine. The device mainly comprises three parts, namely a gas compressor, a combustion chamber and a turbine; the air compressor sucks air from the external atmospheric environment, and compresses the air step by step to pressurize the air, and meanwhile, the air temperature is correspondingly increased; compressed air is pumped into a combustion chamber and is mixed with injected fuel to be combusted to generate high-temperature and high-pressure gas; then the gas or liquid fuel enters a turbine to do work through expansion, the turbine is pushed to drive the gas compressor and the external load rotor to rotate at a high speed, the chemical energy of the gas or liquid fuel is partially converted into mechanical work, and the mechanical work can be output by connecting a generator.
The turbine is one of the key hot end components of the micro-combustion engine, the working environment of the turbine is severe, the structure of the turbine is complex, and the turbine is a component with multiple mechanical faults. The turbine on the one hand influences the efficiency and economy of a miniature combustion engine and on the other hand also determines the safety of the combustion engine. In order to ensure the safe operation of the micro-combustion engine, the turbine should have high safety and reliability under the action of centrifugal force, aerodynamic force, thermal stress and the like, wherein the problem of fracture should be focused. Therefore, when the turbine is designed, static strength analysis is needed to ensure that the structure meets the strength requirement. Most of the past researches are limited to the establishment of a turbine hole corner crack model by adopting a finite element method or the structural optimization of a high-load turbine by adopting ANSYS, and the researches on the modeling analysis aspect of the single-sector turbine by adopting the finite element method are insufficient.
Disclosure of Invention
In view of the above prior art, the present invention provides a method for preventing the crack initiation of a turbine in the design stage of the turbine, so as to make up for the gap in the prior art.
The invention is realized by the following technical scheme:
a method of preventing turbine crack initiation, comprising:
simulating and calculating the stress distribution of the single-sector turbine based on the analysis model of the turbine;
based on the results of the stress distribution, performing structural optimization on an analysis model of the turbine to reduce local stress under the condition that the stress of the turbine structure is determined to exceed the maximum allowable stress;
judging the rationality of the structural optimization;
in response to determining that the structural optimization is reasonable, structurally optimizing the turbine based on spline curves determined by the structural optimization.
Further, the calculating the stress distribution of the single-sector turbine includes: and calculating the stress distribution of the single-sector turbine by adopting a finite element method.
Further, the calculating the stress distribution of the single-sector turbine by using the finite element method comprises the following steps:
s1, setting stress distribution calculation conditions;
s2, dividing grids;
s3, establishing a finite element model, and judging the convergence of the grid;
and S4, performing stress analysis under the condition that the finite element model calculation result is determined to pass the grid convergence test.
Further, the setting of the stress distribution calculation condition includes: the centrifugal force is used as a main load, the boundary conditions are set as circumferential constraint and axial constraint of the hole edge, and the cyclic symmetry conditions are set at the same time.
Further, the partitioning the grid includes: the blade and the wheel disc are independently divided into grids, all adopt hexahedron units, and are bound on a contact surface to limit relative displacement.
Further, the establishing a finite element model and the determining mesh convergence include: establishing five finite element models with different unit sizes, and selecting the maximum Mises, radial stress, circumferential stress, axial stress and maximum principal stress to judge the grid convergence.
Further, the performing structural optimization on the turbine comprises: the weight of the turbine is reduced.
Still further, the reducing the weight of the turbine includes: and based on the spline curve determined by the structure optimization, grooving and excavating the hole on the turbine structure, wherein the geometric shapes of the groove and the hole are determined according to the spline curve.
Further, the judging the reasonableness of the structural optimization comprises the following steps: and performing stress distribution calculation on the optimized turbine analysis model, and determining that the structural optimization is reasonable or preliminarily determining that the structural optimization is reasonable if the maximum stress point of the optimized turbine structure is already yielded and the stress is still less than the allowable stress.
Still further, the judging the reasonableness of the structural optimization includes: and after the structural optimization is preliminarily determined to be reasonable, judging the reasonability of the pneumatic efficiency of the optimized turbine analysis model, and determining that the structural optimization is reasonable under the condition of determining that the pneumatic efficiency is reasonable. The method for preventing the turbine crack from being initiated calculates the stress distribution of the single-sector turbine by adopting a finite element method, and performs structural optimization on an analysis model of the turbine (based on a spline curve determined by the structural optimization, grooving and grooving are performed on the turbine structure, wherein the geometric shapes of the grooves and the holes are determined according to the spline curve). By using the method for preventing the turbine crack from growing, the maximum Mises stress of an analysis model of the turbine before structural optimization reaches 947MPa and exceeds the allowable static strength stress 821MPa of the material; the maximum Mises stress of the turbine after optimization is 805MPa, which shows that the optimization strategy is effective. Therefore, the method provided by the invention is used for carrying out structural optimization on the turbine in the design and development stage of the turbine, and can prevent the turbine from generating cracks in the use stage to a certain extent.
The various terms and phrases used herein have the ordinary meaning as is well known to those skilled in the art. To the extent that the terms and phrases are not inconsistent with known meanings, the meaning of the present invention will prevail.
Description of the drawings:
FIGS. 1a, b, c: turbine geometry model schematic before optimization.
FIG. 2: a method flowchart for preventing turbine crack initiation.
FIG. 3: and (5) a stress calculation result and a relative error data schematic diagram of different models.
FIG. 4: optimizing the stress distribution schematic diagram of the front turbine Mises.
Fig. 5a, b: and (5) optimizing the turbine geometric model schematic diagram.
FIG. 6: and (4) optimizing the stress distribution schematic diagram of the turbine Mises.
Detailed Description
The present invention will be further described with reference to the following examples. However, the scope of the present invention is not limited to the following examples. It will be understood by those skilled in the art that various changes and modifications may be made to the invention without departing from the spirit and scope of the invention.
The present invention has been described generally and/or specifically with respect to materials used in testing and testing methods. Although many materials and methods of operation are known in the art for the purpose of carrying out the invention, the invention is nevertheless described herein in as detail as possible.
The instruments, reagents, materials and the like used in the following examples are conventional instruments, reagents, materials and the like in the prior art and are commercially available in a normal manner unless otherwise specified. Unless otherwise specified, the experimental methods, detection methods, and the like described in the following examples are conventional experimental methods, detection methods, and the like in the prior art.
Example 1 method of preventing turbine crack initiation
The method for preventing the crack initiation of the turbine is provided, and the material of the processed turbine is selected from K424 high-temperature alloy. The K424 alloy is a novel cast nickel-based high-temperature alloy which is independently developed in China, has high-temperature strength, good plasticity and manufacturability and high comprehensive performance, and is suitable for manufacturing turbine rotor blades, guide blades and other parts which work below 950 ℃.
As shown in fig. 1a, b and c, the geometric model of the turbine has 12 blades, the radius of a wheel disc is 37mm, and the radius of a central hole matched with a shaft is 4.5 mm.
Specific material parameters for the K424 cast superalloy are shown in Table 1.
TABLE 1 Material parameters (600 ℃ C.) for the K424 alloy
The method for preventing the turbine crack from being initiated comprises the following steps as shown in figure 2:
(1) and (3) simulating and calculating the stress distribution of the single-sector turbine based on the turbine analysis model: calculating the stress distribution of the single-sector turbine by adopting a finite element method, wherein the stress distribution comprises the following steps S1-S4:
s1: setting stress distribution calculation conditions;
specifically, the design rotating speed of the turbine is 140000rpm (revolutions per minute), and the turbine is subjected to loads such as centrifugal force, thermal stress and aerodynamic force during the working process; considering that the hub of the micro gas turbine has a small diameter and a high rotating speed, the thermal stress and the aerodynamic force caused by temperature difference are neglected, and the centrifugal force is considered as the main load; the boundary conditions are set as hole edge circumferential constraint and axial constraint, and meanwhile, cyclic symmetry conditions are set.
S2: dividing grids;
specifically, the blade and the wheel disc are separately meshed, hexahedral units are adopted, and binding (tie) is carried out on the contact surface to limit relative displacement.
S3: establishing a finite element model and judging the convergence of the grids;
specifically, in order to balance the calculation time length and efficiency, five finite element models with different unit sizes are established together, and the maximum Mises, the radial direction, the circumferential direction, the axial direction and the maximum principal stress are selected for judging the grid convergence.
The finite element model and the calculation results are shown in Table 2.
TABLE 2 stress calculation results for different finite element models
Wherein the global cell size of Model-4 is the same as that of Model-3, but Model-4 is mesh subdivided in the stress concentration regions.
For Mises stress and hoop stress as examples, the results of the different models and the relative error from the previous model are shown in FIG. 3.
As can be seen from the comparison of Model-3, Model-4 and Model-5, the relative difference of the stresses other than the axial stress is within 2%, and the relative difference of the axial stress is within 10%, so that the calculation result can be considered to pass the mesh convergence test.
S4: in the case where the finite element model calculation result passes the mesh convergence test in the determination step S3, stress analysis is performed.
Specifically, Model-4 was selected as the calculation Model, and there were 94760 hexahedral cells, and the corresponding stress distribution is shown in fig. 4. It can be seen that the maximum Mises stress occurs near the end face at the hole edge and reaches 946.9 MPa. The strength limit of the material is 985MPa, the safety coefficient is 1.2, and the maximum allowable stress of the static strength can be obtained as follows: 985/1.2 ═ 821 MPa.
The stress of the turbine structure exceeds the maximum allowable stress, and structural optimization is needed to reduce local stress.
(2) Based on the stress analysis result in the step (1), carrying out structural optimization on an analysis model of the turbine under the condition that the stress of the turbine structure is determined to exceed the maximum allowable stress, specifically: the weight of the turbine is reduced; more specifically, based on a spline curve determined by structure optimization, grooving and grooving the turbine structure, wherein the geometric shapes of the grooves and the holes are determined according to the spline curve; the optimized structure is shown in fig. 5a and 5 b.
(3) Judging the reasonability of structural optimization, responding to the fact that the structural optimization is reasonable, and carrying out structural optimization on the turbine based on a spline curve determined by the structural optimization: and (4) for the optimized turbine analysis model, performing the stress distribution calculation of the steps S1-S4, and determining that the structural optimization is reasonable or preliminarily determining that the structural optimization is reasonable when the maximum stress point yields and the stress is still less than the allowable stress. Wherein, preliminarily determining the structural optimization may be a precondition for determining the structural optimization.
Further, after the structural optimization is preliminarily determined to be reasonable, the pneumatic efficiency reasonability of the optimized turbine analysis model is judged, and the structural optimization is determined to be reasonable under the condition that the pneumatic efficiency is determined to be reasonable.
Wherein the step of determining the rationality of the aerodynamic efficiency of the optimized turbine analysis model may comprise:
calculating the aerodynamic efficiency of the optimized turbine analysis model, and determining that the aerodynamic efficiency is reasonable under the condition that the aerodynamic efficiency is determined to be within a predetermined aerodynamic efficiency threshold range; or calculating the aerodynamic efficiency of the optimized turbine analysis model and the aerodynamic efficiency of the turbine analysis model before optimization, and determining that the aerodynamic efficiency is reasonable under the condition that the difference value of the aerodynamic efficiency and the aerodynamic efficiency is within a predetermined difference value range.
Specifically, as shown in fig. 6, it can be seen that the hole edge stress near the end face is significantly reduced due to the weight reduction, the maximum stress point has already yielded, but the stress is still less than the allowable stress. The gouging and perforations result in increased stress due to stress concentrations, but within acceptable limits. While pneumatic calculations show that the efficiency reduction due to gas flow leakage etc. is not significant, such optimization is considered reasonable.
Although the specific embodiments of the present invention have been described with reference to the examples, the scope of the present invention is not limited thereto, and those skilled in the art will appreciate that various modifications and variations can be made without inventive effort by those skilled in the art based on the technical solution of the present invention.
Claims (10)
1. A method of preventing turbine crack initiation, comprising:
simulating and calculating the stress distribution of the single-sector turbine based on the analysis model of the turbine;
based on the results of the stress distribution, performing structural optimization on an analysis model of the turbine to reduce local stress under the condition that the stress of the turbine structure is determined to exceed the maximum allowable stress;
judging the rationality of the structural optimization;
in response to determining that the structural optimization is reasonable, structurally optimizing the turbine based on spline curves determined by the structural optimization.
2. The method of preventing turbine crack initiation as claimed in claim 1 wherein said calculating a stress distribution for a single sector turbine comprises: and calculating the stress distribution of the single-sector turbine by adopting a finite element method.
3. The method for preventing the initiation of turbine cracks according to claim 2, wherein the calculating the stress distribution of the single-sector turbine by using a finite element method comprises:
s1, setting stress distribution calculation conditions;
s2, dividing grids;
s3, establishing a finite element model, and judging the convergence of the grid;
and S4, performing stress analysis under the condition that the finite element model calculation result is determined to pass the grid convergence test.
4. The method of preventing turbine crack initiation as claimed in claim 3, wherein the setting of stress distribution calculation conditions includes: the centrifugal force is used as a main load, the boundary conditions are set as circumferential constraint and axial constraint of the hole edge, and the cyclic symmetry conditions are set at the same time.
5. The method of preventing turbine crack initiation as claimed in claim 3 wherein the meshing comprises: the blade and the wheel disc are independently divided into grids, all adopt hexahedron units, and are bound on a contact surface to limit relative displacement.
6. The method of claim 3, wherein the establishing a finite element model and the determining the convergence of the mesh comprise: establishing five finite element models with different unit sizes, and selecting the maximum Mises, radial stress, circumferential stress, axial stress and maximum principal stress to judge the grid convergence.
7. The method of preventing turbine crack initiation as claimed in claim 1 wherein the structural optimization of the turbine includes: the weight of the turbine is reduced.
8. The method of preventing turbine crack initiation as claimed in claim 7 wherein reducing the turbine weight comprises: and based on the spline curve determined by the structure optimization, grooving and excavating the hole on the turbine structure, wherein the geometric shapes of the groove and the hole are determined according to the spline curve.
9. The method of preventing turbine crack initiation as claimed in claim 1, wherein said determining the reasonableness of the structural optimization comprises: and performing stress distribution calculation on the optimized turbine analysis model, and determining that the structural optimization is reasonable or preliminarily determining that the structural optimization is reasonable if the maximum stress point of the optimized turbine structure is already yielded and the stress is still less than the allowable stress.
10. The method of preventing turbine crack initiation as claimed in claim 9, wherein said determining the reasonableness of the structural optimization comprises: and after the structural optimization is preliminarily determined to be reasonable, judging the reasonability of the pneumatic efficiency of the optimized turbine analysis model, and determining that the structural optimization is reasonable under the condition of determining that the pneumatic efficiency is reasonable.
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2021
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