CN114004039A - Prediction method for air film hole shape and position parameters and hole depth of aero-engine hollow turbine blade - Google Patents
Prediction method for air film hole shape and position parameters and hole depth of aero-engine hollow turbine blade Download PDFInfo
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Abstract
An aeroengine hollow turbine blade air film hole shape and position parameter and hole depth prediction method belongs to the technical field of precision manufacturing. The method comprises the following steps: 1) preprocessing three-dimensional point cloud original data of a blade actual measurement model; 2) carrying out three-dimensional registration on the measurement model data and the design model data; 3) spline fitting is carried out on the two-dimensional point cloud data of the measuring section; 4) analyzing the bending and torsional deformation of the two-dimensional profile of the blade; 5) calculating the shrinkage deformation of the designed central point of the blade air film hole; 6) and (3) compensating the bending, twisting and shrinkage deformation of the two-dimensional section of the blade to obtain the hole shape and position parameters and the hole depth prediction result of the blade air film. The bending, twisting and shrinkage deformation of the hollow turbine blade of the aircraft engine in the casting forming process are compensated, the center coordinates of the blade air film hole and the actual hole depth processing parameters are predicted and corrected, the positioning precision of the blade air film hole in the actual processing process is improved, and the damage degree of the back wall of the blade air film hole in the actual processing process is reduced.
Description
Technical Field
The invention belongs to the technical field of precision manufacturing, and particularly relates to a prediction method for the hole shape and position parameters and the hole depth of an air film of an aero-engine hollow turbine blade.
Background
In order to improve the high-temperature creep resistance of a hot end part of a hollow turbine blade of an aeroengine and ensure that the hot end part can reliably serve for a long time under the working conditions of strong thermal shock and complex cycle thermal stress, an effective cooling measure must be adopted; the air film cooling technology is widely applied as an effective means for improving the temperature bearing and bearing capacity of the blade. The air film cooling is to design a large number of micro through holes with the aperture of about 0.1-0.8 mm and the hole depth of more than 3mm on the surface profile of the turbine blade, and a thin-layer cold air film is formed on the surface of a component by utilizing cold air released inside the component and through convection in the micro through holes so as to achieve the purpose of isolating the high-temperature combustion gas flow to protect the component. The air film cooling efficiency is the response of parameters such as materials, geometry and the like and the coupling effect thereof under a high-temperature high-pressure three-dimensional unsteady flow field, wherein the distribution position of air film holes determines the transverse coverage width and the longitudinal coverage length of a cooling air film; therefore, ensuring the geometric accuracy of blade film hole machining is important for improving the cooling efficiency and the energy efficiency of the engine.
In the actual turbine blade casting forming process, the volume change of the actual solidification cooling process of the blade is restricted by the outside or the blade, the cooling shrinkage is blocked to generate thermal stress strain, and finally the blade shape is bent, twisted and shrunk to deform, which is shown as the displacement deviation between the surface point of the blade and the corresponding point on the design model, so that the design parameter of the air film hole on the design model of the turbine blade is not consistent with the actual processing parameter, the accurate positioning of the processing of the air film hole of the turbine blade is difficult, the depth measurement of the air film hole is difficult, and the like, thereby reducing the temperature bearing and bearing capacity of the hollow turbine blade.
At present, more domestic researches only stay in the fields of turbine blade profile analysis, error analysis and compensation in the air film hole machining process, turbine blade mold reverse deformation design and the like, and the actual machining deformation and position parameter prediction and hole depth prediction of turbine blade air film holes are few and almost blank. In foreign countries, the british roche company, the american general and general companies have all realized the manufacture of high-performance air film cooling hollow turbine blades, but some key technologies including air film hole machining and measurement are strictly forbidden to China. Therefore, the method for predicting the shape and position parameters of the air film hole and the hole depth of the hollow turbine blade of the aero-engine has important significance for improving the processing and positioning precision of the air film hole and reducing the damage of the back wall of the punched hole.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the prediction method for the shape and position parameters and the hole depth of the air film hole of the aero-engine hollow turbine blade, which can effectively predict the actual shape and position parameters and the actual hole depth of the air film hole of the turbine blade, improve the processing and positioning precision of the air film hole of the turbine blade and reduce the damage of the back wall of a punched hole.
The invention comprises the following steps:
1) preprocessing three-dimensional point cloud original data of a blade actual measurement model;
2) carrying out three-dimensional registration on the measurement model data and the design model data;
3) spline fitting is carried out on the two-dimensional point cloud data of the measuring section;
4) analyzing the bending and torsional deformation of the two-dimensional profile of the blade;
5) calculating the shrinkage deformation of the designed central point of the blade air film hole;
6) and (3) compensating the bending, twisting and shrinkage deformation of the two-dimensional section of the blade to obtain the hole shape and position parameters and the hole depth prediction result of the blade air film.
In step 1), the pretreatment may specifically include:
(1) filtering noise points which have influence on analysis and calculation by a point cloud filtering and noise reduction method; and if the noise points which cannot be filtered out by filtering exist, manually filtering by adopting a man-machine interactive point cloud cutting method.
(2) By means of a curvature-based point cloud simplification method, multi-sampling is carried out on a region with a large blade contour curvature, and less sampling is carried out on a region with a small curvature, so that three-dimensional point cloud original data are simplified, and analysis and calculation efficiency is improved on the premise of ensuring calculation accuracy;
(3) and carrying out point cloud smoothing operation based on least square translation on the burr influence area so as to obtain the profile data of the actual blade measurement model which is easy to analyze and accurate.
In step 2), the specific method for performing three-dimensional registration on the measurement model data and the design model data may be: based on a singular value decomposition algorithm, a method of picking up feature point pairs corresponding to a design model and a measurement model through man-machine interaction is adopted to perform pre-registration operation of the two models, so that the initial spatial poses of the two models are as close as possible; based on the model pre-registration effect, the designed model and the measured model are accurately registered by adopting a point-to-surface ICP improved algorithm, so that the space pose difference between the measured section of the blade and the corresponding designed section is in the convergence domain of the two-dimensional ICP algorithm.
In step 3), the specific method for performing spline fitting on the two-dimensional point cloud data of the measurement cross section may be: and intercepting two-dimensional point cloud data of the profile surface of the measurement model at the position of the central coordinate Z value of the air film hole, and carrying out spline curve fitting processing on the data by adopting a bubble sorting algorithm and a least square algorithm based on a distance threshold.
In step 4), the specific method for analyzing the two-dimensional profile bending and torsional deformation of the blade may be: carrying out equidistant discrete processing on the two-dimensional profile curve of the design model at the same Z value, registering the point data of the blade design model and the two-dimensional profile curve of the actual measurement model by a point-to-line ICP (inductively coupled plasma) registration algorithm, wherein after three-dimensional registration, the difference of the spatial poses of the blade measurement section and the corresponding design section is in the convergence domain of the two-dimensional ICP algorithm, and a 4 x 4 matrix obtained by point-to-line ICP algorithm registration is a bending-twisting deformation matrix of the measurement model and the design model at the section;
in the step 5), the step of calculating the shrinkage deformation at the designed central point of the blade air film hole is to compensate the bending deformation obtained in the step 4), and the relative displacement from all discrete points of the designed section line to the nearest point on the blade measuring section line is calculated to obtain the shrinkage deformation of each point;
in step 6), the specific steps of obtaining the blade gas film hole shape and position parameters and the hole depth prediction result may be:
(1) compensating the bending, twisting and shrinkage deformation obtained in the steps 3) to 5) to obtain new positioning parameters for actually processing the air film hole;
(2) and calculating the original wall thickness parameter of the section, performing shrinkage deformation compensation on the original wall thickness parameter, designing parameters according to a gas film hole method vector, and calculating the actual predicted hole depth of the gas film hole based on the triangular pythagorean theorem so as to obtain the new hole depth data of the actual processing of the gas film hole.
The method compensates bending, torsion and shrinkage deformation of the hollow turbine blade of the aircraft engine in the casting and forming process, predicts and corrects the center coordinates of the gas film hole of the blade and the actual processing parameters of the hole depth, improves the positioning precision of the gas film hole of the blade in the actual processing process, reduces the damage degree of the back wall of the gas film hole of the blade in the actual processing process, and has certain promotion effect on the development of the precision manufacturing research field of the hollow turbine blade of the aircraft engine in China.
Drawings
FIG. 1 is a schematic view of a profile of an actual measurement model of a blade.
Fig. 2 is a schematic diagram of a three-dimensional registration process.
Fig. 3 is a schematic diagram of a two-dimensional registration process. Wherein, the left diagram is a schematic diagram before the bending deformation compensation, and the right diagram is a schematic diagram of the bending deformation compensation.
Fig. 4 is a schematic diagram of shrinkage deformation compensation calculation of each point after two-dimensional registration.
FIG. 5 is a schematic illustration of the prediction of the pore depth of the film by any amount of cross-sectional shrinkage. Wherein a is the two-dimensional wall thickness at the center of the hole calculated after compensation of bending and shrinkage deformation, b is the predicted hole depth of the air film hole, and alpha is the axial inclination angle of the hole.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1 to 5, the method for predicting the air film hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade of the present invention comprises the following steps:
s1, preprocessing three-dimensional point cloud original data of the actual blade measurement model: preprocessing three-dimensional point cloud original data of a blade actual measurement model acquired through laser scanning, denoising the original point cloud data through a statistical filtering algorithm, filtering out noise miscellaneous points which have influence on splicing effect, denoising the statistical filtering noise miscellaneous points which cannot be filtered out, and further manually cutting the original point cloud original data through a point cloud cutting method of human-computer interaction; performing point cloud smoothing by a least square translation algorithm to remove burr parts of point cloud data; mass point cloud data of the measurement model are simplified through a point cloud simplification algorithm based on curvature, the analysis and calculation efficiency is improved on the premise of ensuring the calculation precision, and an accurate blade actual measurement model outline is obtained, as shown in fig. 1;
s2, carrying out three-dimensional registration on the measurement model data and the design model data: surface sampling is carried out on the blade design model, three-dimensional outline point cloud data of the blade design model are obtained, and the three-dimensional outline point cloud data and the outline data of the blade actual measurement model obtained in the last step are registered; because the difference between the blade design coordinate system and the measurement coordinate system is large, the initial positions of the two models on the space are far, and the shapes of the two models are not completely the same, a man-machine interactive pre-alignment method based on a singular value decomposition algorithm is adopted; based on a singular value decomposition algorithm, pre-registration operation of the two models is carried out by adopting a method of picking up feature point pairs corresponding to the design model and the measurement model through human-computer interaction, so that the initial spatial poses of the two models are as close as possible, a better initial position is obtained, and the local optimal condition of registration is avoided; based on the model pre-registration effect, a point-to-surface ICP improved algorithm is adopted to accurately register the design model and the measurement model, so that the spatial pose difference between the blade measurement section and the corresponding design section is in the convergence domain of the two-dimensional ICP algorithm, a basis is provided for the subsequent two-dimensional bending and twisting analysis, and a three-dimensional registration process is shown in FIG. 2;
s3, performing spline fitting on the two-dimensional point cloud data of the measuring section: intercepting two-dimensional point cloud data of the profile surface of the measurement model at the position of the central coordinate Z value of the air film hole, and performing spline curve fitting processing on the data by adopting a bubble sorting algorithm and a least square algorithm based on a distance threshold;
s4, analyzing the two-dimensional profile bending and torsional deformation of the blade: performing equidistant discrete processing on the two-dimensional profile curve of the design model at the same Z value, registering the point data of the blade design model and the two-dimensional profile curve of the actual measurement model by using a point-to-line ICP (inductively coupled plasma) registration algorithm, wherein after three-dimensional registration, the difference of the spatial poses of the blade measurement section and the corresponding design section is in the convergence domain of the two-dimensional ICP algorithm, so that a 4 x 4 matrix obtained by the point-to-line ICP algorithm registration is a bending-torsional deformation matrix of the measurement model and the design model at the section, and a two-dimensional registration process is shown in FIG. 3;
s5, calculating the shrinkage deformation of the blade air film hole at the design center point: compensating the bending deformation calculated in the step S4, calculating the relative displacement from all discrete points of the designed section line to the nearest point on the blade measuring section line, and obtaining the shrinkage deformation amount of each point, wherein fig. 4 is a calculation schematic diagram of the shrinkage amount of each point after two-dimensional registration;
s6, predicting the pore shape and position parameters and the pore depth of the air film: compensating the bending, twisting and shrinkage deformation of the two-dimensional section of the blade, and compensating the bending, twisting and shrinkage deformation obtained in the steps S3, S4 and S5 to obtain new positioning parameters for actually processing the air film hole; and calculating the original wall thickness parameter of the section at the section, performing shrinkage deformation compensation on the original wall thickness parameter, calculating the actual predicted hole depth of the gas film hole based on the trigonometric pythagorean theorem according to the vector design parameter of the gas film hole, and thus obtaining the new hole depth data of the actual gas film hole processing to obtain the shape and position parameters of the gas film hole of the blade and the hole depth prediction result. FIG. 5 is a schematic illustration of the prediction of the pore depth of the film by any amount of cross-sectional shrinkage.
It should be noted that, in the present invention, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The present invention and its embodiments are described above, and the description is not limited thereto, and what is shown in the drawings is only one embodiment of the present invention, and the actual solution is not limited thereto. In conclusion, those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiments as a basis for designing or modifying other structures for carrying out the same purposes of the present invention without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. The prediction method of the air film hole shape and position parameters and hole depths of the air film of the hollow turbine blade of the aero-engine is characterized by comprising the following steps:
1) preprocessing three-dimensional point cloud original data of a blade actual measurement model;
2) carrying out three-dimensional registration on the measurement model data and the design model data;
3) spline fitting is carried out on the two-dimensional point cloud data of the measuring section;
4) analyzing the bending and torsional deformation of the two-dimensional profile of the blade;
5) calculating the shrinkage deformation of the designed central point of the blade air film hole;
6) and (3) compensating the bending, twisting and shrinkage deformation of the two-dimensional section of the blade to obtain the hole shape and position parameters and the hole depth prediction result of the blade air film.
2. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade air film according to claim 1, wherein in the step 1), the preprocessing comprises the following specific steps:
(1) filtering noise points which have influence on analysis and calculation by a point cloud filtering and noise reduction method;
(2) by means of a curvature-based point cloud simplification method, multi-sampling is carried out on a region with a large blade contour curvature, and less sampling is carried out on a region with a small curvature, so that three-dimensional point cloud original data are simplified, and analysis and calculation efficiency is improved on the premise of ensuring calculation accuracy;
(3) and carrying out point cloud smoothing operation based on least square translation on the burr influence area so as to obtain the profile data of the actual blade measurement model which is easy to analyze and accurate.
3. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade air film according to claim 1, wherein in the step 2), the specific method for performing three-dimensional registration on the measurement model data and the design model data comprises the following steps: based on a singular value decomposition algorithm, a method of picking up feature point pairs corresponding to a design model and a measurement model through man-machine interaction is adopted to perform pre-registration operation of the two models, so that the initial spatial poses of the two models are as close as possible; based on the model pre-registration effect, the designed model and the measured model are accurately registered by adopting a point-to-surface ICP improved algorithm, so that the space pose difference between the measured section of the blade and the corresponding designed section is in the convergence domain of the two-dimensional ICP algorithm.
4. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade air film according to claim 1, wherein in the step 3), the specific method for performing spline fitting on the two-dimensional point cloud data of the measured section comprises the following steps: and intercepting two-dimensional point cloud data of the profile surface of the measurement model at the position of the central coordinate Z value of the air film hole, and carrying out spline curve fitting processing on the data by adopting a bubble sorting algorithm and a least square algorithm based on a distance threshold.
5. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade air film according to claim 1, wherein in the step 4), the specific method for analyzing the two-dimensional profile bending and torsional deformation of the blade comprises the following steps: and carrying out equidistant discrete processing on the two-dimensional profile curve of the design model at the same Z value, registering the point data of the blade design model and the two-dimensional profile curve of the actual measurement model by using a point-to-line ICP (inductively coupled plasma) registration algorithm, wherein after three-dimensional registration, the difference of the spatial poses of the blade measurement section and the corresponding design section is in a convergence domain of the two-dimensional ICP algorithm, and a 4 x 4 matrix obtained by point-to-line ICP algorithm registration is a bending-twisting deformation matrix of the measurement model and the design model at the section.
6. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade air film hole as claimed in claim 1, wherein in the step 5), the step of calculating the shrinkage deformation of the blade air film hole design center point is to compensate the bending deformation obtained in the step 4), and the step of calculating the relative displacement from all discrete points of the design section line to the nearest point on the blade measurement section line to obtain the shrinkage deformation amount of each point.
7. The method for predicting the hole shape and position parameters and the hole depth of the aero-engine hollow turbine blade as claimed in claim 1, wherein in the step 6), the specific steps for obtaining the prediction results of the hole shape and position parameters and the hole depth of the blade air film are as follows:
(1) compensating the bending, twisting and shrinkage deformation obtained in the steps 3) to 5) to obtain new positioning parameters for actually processing the air film hole;
(2) and calculating the original wall thickness parameter of the section, performing shrinkage deformation compensation on the original wall thickness parameter, designing parameters according to a gas film hole method vector, and calculating the actual predicted hole depth of the gas film hole based on the triangular pythagorean theorem so as to obtain the new hole depth data of the actual processing of the gas film hole.
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