CN114218841A - Multilayer film coupling stress simulation calculation method under action of thermal-centrifugal load - Google Patents
Multilayer film coupling stress simulation calculation method under action of thermal-centrifugal load Download PDFInfo
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Abstract
The invention provides a simulation calculation method for coupling stress of a multilayer film under the action of a thermal-centrifugal load, which comprises the following specific steps: the method comprises the following steps: establishing a turbine blade substrate model: step two: the surface temperature distribution of the turbine blade under the heat load is obtained through simulation: step three: simulating to obtain the surface strain distribution of the turbine blade under the centrifugal load: step four: theoretically calculating the internal stress of each layer of film: step five: constructing a blade substrate-multilayer film structure model simulation model: step six: and (5) simulating and calculating the internal stress of the multilayer film structure. When the turbine blade structure is complex, the blade-film sensor model is difficult to model, or the film grid size is small, and the simulation calculation efficiency is low, the coupling stress value of each layer of film can be theoretically calculated according to the blade surface temperature field and the centrifugal strain field, and the method has the advantages of simplicity and high accuracy.
Description
Technical Field
The invention relates to a simulation calculation method for coupling stress of a multilayer film thermocouple sensor applied to a turbine blade, which is particularly suitable for the simulation calculation of the coupling stress of a multilayer film structure under the action of thermal load and centrifugal load under the working condition of the turbine blade.
Background
The surface temperature of the turbine blades of the engine has important influence on the performance and the service life of the engine, and the accurate measurement of the temperature of the surface under the working condition is important. The film thermocouple is directly deposited on the surface of the turbine blade and carries out real-time temperature measurement, and the thickness of the film thermocouple is in the micro-nano level. The typical thin-film thermocouple sensor is composed of a multilayer film and is divided into a transition layer, an insulating layer, a functional layer and a protective layer from inside to outside according to functions. The preparation method of the film suitable for the turbine blade is multi-source ion beam co-sputtering, and the film with continuity, uniformity, compactness and strong adhesion can be prepared on a large-size and large-angle curved surface alloy substrate workpiece.
The operating temperature of the turbine engine during operation can reach 1300 ℃, and due to the fact that the thermal expansion coefficients of materials of all layers of the film sensor are mismatched, high thermal stress is introduced into the multilayer film structure by external temperature load. In addition to the thermal stress created by the thermal mismatch, substrate deformation will also introduce elastic stress in the film. When the engine blade works, the action of centrifugal load can generate radial tensile stress action on the blade, and further generate radial tensile strain. The film has extremely low mass, the centrifugal stress generated in the film can be ignored, but the film sensor is directly plated on the blade, the strain on the surface of the blade is directly transmitted to the film, and the stress action is generated in the film. Due to the different elastic modulus of each layer of film material, the surface strain of the substrate will also produce a stress mismatch effect in the film structure.
The internal stress of the film causes failure modes such as warping, peeling, cracking and the like of the structure, and after cracking, the sensitive material is likely to be oxidized and broken, so that the film sensor fails.
Disclosure of Invention
The invention aims to provide a theoretical calculation and simulation calculation method suitable for internal stress generated by mismatching of thermal expansion coefficients and elastic moduli of materials of all layers of a turbine blade multilayer film thermocouple sensor under the action of thermal load and centrifugal load. In particular to a turbine blade surface temperature field and a centrifugal strain field obtained through simulation, and theoretically calculating the coupling stress of each layer of film of a multilayer film sensor plated on the surface of a blade. And provides a coupling stress simulation method of the blade substrate-film sensor model.
The invention is realized by the following steps:
the method comprises the following steps: establishing a turbine blade substrate model:
s11, obtaining turbine blade material parameters: the elastic modulus E of the turbine blade is obtained by inquiring a material performance parameter table through literature investigation or measuring by adopting a pulse excitation method, an acoustic resonance method, a static method and the likefPoisson ratio vfCoefficient of thermal expansion αfDensity G off;
And S12, creating a turbine blade structure model by using ANSYS software, wherein the created model is shown in FIG. 1a and FIG. 1 b. Completing geometric modeling and defining material parameters, wherein the specific parameter type to be defined is the elastic modulus E obtained in S11fPoisson ratio vfCoefficient of thermal expansion αfDensity G offThe model is subjected to grid division, the type of Element Size division is adopted, the Element Size parameter is set to be 5e-3, and the division result is shown in figure 2.
S13, applying displacement constraint conditions, and applying axial and circumferential displacement constraints to the tenon; the inside of the cylindrical surface of the spider imposes a cylindrical constraint, as in figure 3.
Step two: the surface temperature distribution of the turbine blade under the heat load is obtained through simulation:
selecting a measuring point, and measuring to obtain surface temperature values of different positions of the turbine blade under the working condition; applying a temperature value to the position of the measurement point corresponding to the blade model, and solving by a solver in ANSYS to obtain a model surface temperature field T, as shown in FIG. 4a and FIG. 4 b.
Step three: simulating to obtain the surface strain distribution of the turbine blade under the centrifugal load:
the working condition of the turbine blade engine is inquired to obtain the rotating speed (6000rad/s) of the turbine blade during working; and applying a rotating speed to the cylindrical surface of the wheel disc, and solving the centrifugal strain field epsilon of the surface of the turbine blade by utilizing the solver simulation of ANSYS workbench, as shown in FIGS. 5a and 5 b.
Step four: theoretically calculating the internal stress of each layer of film:
s41, obtaining material parameters of each layer of the substrate and the film: the elastic modulus, the poisson ratio, the thermal expansion coefficient and the density of each layer of film material are obtained by measuring or looking up a table in the S11 mode, and the specific formula is shown in the following table;
s42, obtaining the internal stress sigma of each layer of film by substituting the surface temperature field T obtained in the second step and the surface centrifugal strain field epsilon obtained in the third step into the following formulax,i。
In the formula, EiIs the elastic modulus, alpha, of the ith layer materialsIs the coefficient of thermal expansion of the substrate, alphaiIs the coefficient of thermal expansion, v, of the ith layer of materialiIs the poisson's ratio of the ith layer of material. T isxIs the blade surface temperature at position x, T0The initial temperature of the blade, i.e. the sensor, is generally taken as room temperature, epsilonxIs the blade surface strain at position x.
Step five: constructing a blade substrate-multilayer film structure model simulation model:
s51, using ANSYS software to create a blade substrate-multilayer film structure model, wherein the main structure of the turbine blade is composed of a blade body, a flange plate and a tenon, and the turbine blade internally comprises a cooling hole and a cooling cavity structure. The film sensor is plated on the blade body and extends from the blade root to the blade tip. Simplifying a turbine blade model to be modeled, simplifying a flange plate and a tenon into a block body with a cylindrical surface at the bottom, and recording the block body as the bottom of a blade; the blade body is simplified into a rectangular plate.
The film sensor has a structure of substrate, transition layer, insulating layer, functional layer and protective layer, and the bottom transition layer is 1um NiCrAlY and 2um Al2O3Film, insulating layer of 2um Ta2O5And 2um SiO2The functional layer is 0.5um NiCr/NiSi film, and the protective layer is 4um SiO2A film.
In a simplified blade model, the blade body of the turbine blade is simplified into a cuboid structure with the size of 10cm by 2cm, the thickness of the cuboid structure is 1cm, and the size of the thin film sensor is 8cm by 1 cm; the thickness and parameters of each layer of film from bottom to top of the substrate are specifically shown in the table of S41, completing geometric modeling and defining the material parameters in the table. Performing mesh division on the model, thinning meshes of the film part, adopting an Element Size division type for the 6-layer film part, setting an Element Size parameter to be 5e-4, and setting a modeling and mesh division result as shown in FIG. 6; binding contact is set between the substrate and the film and between the substrate and the film.
The schematic diagram of the thin film sensor structure is shown in FIG. 7.
S52, applying displacement constraint conditions, and applying full constraint (namely complete fixation) to the bottom surface of the simplified blade; applying axial and circumferential displacement constraints to the side surfaces of the bottom of the blade; and applying cylindrical restraint to the inner side of the bottom cylindrical surface.
Step six: and (3) simulating and calculating the internal stress of the multilayer film structure:
s61, according to the blade surface temperature field, applying temperature values to the film-substrate model key points, and solving through an ANSYS workbench solver to obtain a model temperature field, as shown in FIG. 8.
S62, applying 6000rad rotation speed to the bottom cylindrical surfaces, simulating by using a solver of ANSYS workbench to obtain the internal stress sigma of each layer of film under the coupling action of the temperature load and the centrifugal loadx,iAs in fig. 9.
The theoretical calculation method of the thermal-centrifugal coupling stress applied to the multilayer film thermocouple sensor of the turbine blade comprises the steps of firstly, adopting ANSYS software to establish a finite element model of a turbine blade structure, and obtaining a temperature field and a centrifugal strain field of the surface of the turbine blade through simulation analysis; and calculating the thermal-centrifugal coupling stress value of each layer of film by using a theoretical formula based on the surface temperature field and the centrifugal strain field of the blade. When the turbine blade structure is complex, the blade-film sensor model is difficult to model, or the film grid size is small, and the simulation calculation efficiency is low, the coupling stress value of each layer of film can be theoretically calculated according to the blade surface temperature field and the centrifugal strain field, and the method has the advantages of simplicity and high accuracy.
The invention also provides a simulation calculation method of the thermal-centrifugal coupling stress of the multilayer thin film thermocouple sensor, a finite element model of the blade substrate-multilayer thin film structure is established by using ANSYS software, the coupling stress value is obtained through simulation analysis, and the coupling stress value and a theoretical result can be verified mutually.
Drawings
FIG. 1a is a suction side of a finite element model of a turbine blade.
FIG. 1b is a pressure side of a finite element model of a turbine blade.
FIG. 2 shows the meshing results of the turbine blade model.
FIG. 3 is a schematic illustration of turbine blade constraints and the dovetail and disk cylinder.
FIG. 4a is a cloud graph of a temperature field distribution of a pressure side of a turbine blade.
FIG. 4b is a cloud chart of the temperature field distribution of the suction surface of the turbine blade.
FIG. 5a is a cloud of centrifugal load strain distributions for the pressure side of a turbine blade.
FIG. 5b is a cloud of the centrifugal load strain distribution of the suction surface of the turbine blade.
FIG. 6 is a simplified blade-substrate simulation model and meshing results.
Fig. 7 is a schematic diagram of a thin film sensor structure.
FIG. 8 is a temperature field distribution of a simplified model.
Fig. 9a is a substrate-film model coupling stress distribution (macroscopic).
Fig. 9b is a substrate-film model coupled stress distribution (longitudinal cross section).
FIG. 10 is a flow chart of the method of the present invention.
FIG. 11a is a NiCr layer coupling stress distribution.
FIG. 11b is SiO2The layers couple the stress distribution.
Detailed Description
The flow chart of the method of the invention is shown in figure 10. The invention relates to a thin film internal stress calculation method combining theoretical calculation and an ANSYS simulation calculation method, which comprises the following steps:
the method comprises the following steps: establishing a turbine blade substrate model:
s11, obtaining turbine blade material parameters: obtaining the elastic modulus E of the turbine blade by measurement or table lookupfPoisson ratio vfCoefficient of thermal expansion αfDensity G off;
And S12, creating a turbine blade structure model by using ANSYS software, completing geometric modeling, defining material parameters and meshing the model as shown in FIG. 2, wherein the model is shown in FIG. 1a and FIG. 1 b.
S13, applying displacement constraint conditions, and applying axial and circumferential displacement constraints to the tenon; the inside of the cylindrical surface of the spider imposes a cylindrical constraint, as in figure 3.
Step two: the surface temperature distribution of the turbine blade under the heat load is obtained through simulation:
selecting a measuring point, and measuring to obtain surface temperature values of different positions of the turbine blade under the working condition; and applying a temperature value to the position of the measuring point corresponding to the blade model, and solving to obtain a model surface temperature field T. As shown in fig. 4a and 4 b.
Step three: simulating to obtain the surface strain distribution of the turbine blade under the centrifugal load:
obtaining the rotating speed omega, the rotating radius R and the rotating direction of the turbine blade during working; and applying a rotating speed to the cylindrical surface of the wheel disc, and simulating and solving a centrifugal strain field epsilon of the surface of the turbine blade, as shown in fig. 5a and 5 b.
Step four: theoretically calculating the internal stress of each layer of film:
s41, obtaining material parameters of each layer of the substrate and the film: the elastic modulus E of each layer of film material is obtained by measurement or table lookupiPoisson ratio viCoefficient of thermal expansion αiDensity G ofi;
S42, obtaining the internal stress sigma of each layer of film by substituting the surface temperature field T obtained in the second step and the surface centrifugal strain field epsilon obtained in the third step into the following formulax,i。
In the formula, EiIs the elastic modulus, alpha, of the ith layer materialiIs the coefficient of thermal expansion, v, of the ith layer of materialiIs the poisson's ratio of the ith layer of material. T isxIs the blade surface temperature at position x, T0The initial temperature of the blade, i.e. the sensor, is generally taken as room temperature, epsilonxIs the blade surface strain at position x.
Step five: constructing a blade substrate-multilayer film structure model simulation model:
s51, creating a blade substrate-multilayer thin film structure model by using ANSYS software, completing geometric modeling and defining material parameters; meshing the model, and refining partial meshes of the film, as shown in fig. 6; binding contact is set between the substrate and the film and between the film and the film.
S52, applying displacement constraint conditions, and applying full constraint to the bottom surface of the substrate; applying axial and circumferential displacement constraints to the bottom side of the substrate; and applying cylindrical restraint to the inner side of the cylindrical surface at the bottom.
Step six: and (3) simulating and calculating the internal stress of the multilayer film structure:
s61, according to the blade surface temperature field, applying temperature values to the film-substrate model key points, and solving to obtain a model temperature field, as shown in FIG. 7.
S62, aligning the bottom circleRotating speed is applied to the cylindrical surface, and the internal stress sigma of each layer of film under the coupling action of temperature load and centrifugal load is obtained through simulationx,i. As shown in fig. 8.
Example of the implementation
The invention verifies the simulation calculation method of the internal stress of the multilayer film under the action of the thermal-centrifugal load by using a multilayer film thermocouple sensor case applied to the turbine blade of the gas turbine.
The method comprises the following steps: establishing a turbine blade substrate model:
s11, obtaining turbine blade material parameters: the material of the blade is MAR247 alloy, and the elastic modulus E of the turbine blade at the working temperature is obtained by looking up a tablefPoisson ratio vfCoefficient of thermal expansion αfDensity G off;
Young's modulus/GPa | 144 |
Poisson ratio | 0.27 |
Coefficient of thermal expansion | 1.49*10-5 |
Density/kg/ |
8540 |
S12, using ANSYS software to create a turbine blade structure model, completing geometric modeling, defining material parameters, and carrying out grid division on the model.
S13, applying displacement constraint conditions, and applying axial and circumferential displacement constraints to the tenon; and applying cylindrical restraint to the inner side of the cylindrical surface of the wheel disc.
Step two: the surface temperature distribution of the turbine blade under the heat load is obtained through simulation:
s21, selecting a measuring point, and measuring to obtain surface temperature values of different positions of the turbine blade under working conditions;
and S22, applying a temperature value to the position of the measuring point, and solving to obtain a blade surface temperature field. As shown in fig. 4a and 4 b.
Step three: simulating to obtain the surface strain distribution of the turbine blade under the centrifugal load:
and applying a rotating speed of 1400rad/s to the cylindrical surface of the wheel disc, and simulating to solve the centrifugal strain field epsilon on the surface of the blade body. As shown in fig. 5a and 5 b.
Step four: theoretically calculating the internal stress of each layer of film:
s41, obtaining material parameters of each layer of the substrate and the film: obtaining the elastic modulus, Poisson's ratio, thermal expansion coefficient and density of each layer of film material by measurement or table lookup;
s42, obtaining the internal stress sigma of each layer of film by substituting the surface temperature field T obtained in the second step and the surface centrifugal strain field epsilon obtained in the third step into the following formulax,i。
Step five: constructing a multilayer thin film sensor simulation model:
s52, using ANSYS software to create a film-substrate structure model, completing geometric modeling, defining material parameters, and carrying out grid division on the model. When the constraint relationship between the substrate and the film and between the films is set, the bonding contact between the substrate and the film and between the films should be set.
The ANSYS software provides 6 types of surface contact: binding contact, no separation contact, no friction contact, rough contact, frictional contact, tangential resistance sliding contact. Wherein the binding contact (bound) completely limits the normal to tangential relative displacement of the model contact location.
The thin film sensor is generated by sputtering high-speed ions on a substrate through a magnetic control technology, the adhesion mode between the film layers is a mode of combining simple adhesion and diffusion adhesion, and the adhesion effect of a small amount of macroscopic effect can be included by considering the interface defects (micropores and cracks) of the thin film. Before failure occurs, relative displacement or rotation does not occur between the film and the substrate and between the film and the film; and the boundary side of the film has no constraint effect.
Therefore, when the film is subjected to three-dimensional stress analysis, the contact surface of each film which is in contact with each other is set to be in binding contact without considering the defects of the contact interface and the delamination failure problem. The modeling and meshing of the substrate and film structure is shown in fig. 6.
S53, applying displacement constraint conditions, and applying full constraint to the bottom surface of the substrate; applying axial and circumferential displacement constraints to the bottom side of the substrate; and applying cylindrical restraint to the inner side of the cylindrical surface at the bottom.
Step six: and (3) simulating and calculating the internal stress of the multilayer film structure:
and S61, applying temperature values to the key points of the film-substrate model according to the temperature field of the surface of the blade, and solving to obtain the distribution of the temperature field of the model. As shown in fig. 8.
And S62, applying a rotating speed to the bottom cylindrical surface, and simulating to obtain the internal stress distribution of the multilayer film under the coupling action of the temperature load and the centrifugal load. As shown in fig. 9a and 9 b.
And finally, comparing the internal stress obtained by theoretical calculation with an internal stress value obtained by finite element simulation, and verifying the method. As shown in fig. 11a and 11 b.
The result calculated by the method through simulation is proved to be very consistent with the theoretical model result, and the method can be used for the simulation calculation of the coupling stress of the multilayer film.
Claims (9)
1. A simulation calculation method for coupling stress of a multilayer film under the action of a thermal-centrifugal load is characterized by comprising the following specific steps:
the method comprises the following steps: establishing a turbine blade substrate model:
s11, obtaining turbine blade material parameters:
s12, creating a turbine blade structural model using ANSYS software,
s13, applying displacement constraint conditions, and applying axial and circumferential displacement constraints to the tenon; applying cylindrical restraint to the inner side of the cylindrical surface of the wheel disc;
step two: the surface temperature distribution of the turbine blade under the heat load is obtained through simulation:
selecting a measuring point, and measuring to obtain surface temperature values of different positions of the turbine blade under the working condition; applying a temperature value to the position of a measuring point corresponding to the blade model, and solving through a solver in ANSYS to obtain a model surface temperature field T;
step three: simulating to obtain the surface strain distribution of the turbine blade under the centrifugal load:
the working condition of the turbine blade engine is inquired to obtain the rotating speed of the turbine blade during working; applying a rotating speed to the cylindrical surface of the wheel disc, and simulating and solving a centrifugal strain field epsilon on the surface of the turbine blade by using a solver of ANSYS workbench;
step four: theoretically calculating the internal stress of each layer of film:
s41, obtaining material parameters of each layer of the substrate and the film:
s42, obtaining the internal stress sigma of each layer of film by substituting the surface temperature field T obtained in the second step and the surface centrifugal strain field epsilon obtained in the third step into the following formulax,i;
In the formula, EiIs the elastic modulus, alpha, of the ith layer materialsIs the coefficient of thermal expansion of the substrate, alphaiIs the coefficient of thermal expansion, v, of the ith layer of materialiIs poise of the ith materialThe bulk ratio; t isxIs the blade surface temperature at position x, T0The initial temperature of the blade, i.e. the sensor, is generally taken as room temperature, epsilonxIs the blade surface strain at position x;
step five: constructing a blade substrate-multilayer film structure model simulation model:
s51, creating a blade substrate-multilayer thin film structure model by using ANSYS software;
s52, applying displacement constraint conditions and applying full constraint to the bottom surface of the simplified blade; applying axial and circumferential displacement constraints to the side surfaces of the bottom of the blade; applying cylindrical constraint to the inner side of the cylindrical surface at the bottom;
step six: and (3) simulating and calculating the internal stress of the multilayer film structure:
s61, applying temperature values to the film-substrate model key points according to the blade surface temperature field, and solving through an ANSYS workbench to obtain a model temperature field;
s62, applying rotating speed to the bottom cylindrical surface, and obtaining the internal stress sigma of each layer of film under the coupling action of temperature load and centrifugal load by utilizing the simulation of an ANSYS workbenchx,i。
2. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1, wherein the method comprises the following steps: in step S11, the elastic modulus E of the turbine blade is obtained by searching a material performance parameter table through literature investigation or measuring by using a pulse excitation method, an acoustic resonance method or a static methodfPoisson ratio vfCoefficient of thermal expansion αfDensity G off。
3. The simulation calculation method of multilayer film coupling stress under the action of thermal-centrifugal load according to claim 1 or 2, characterized in that: in step S12, a model is established and material parameters are defined, the parameter type being the modulus of elasticity E obtained in S11fPoisson ratio vfCoefficient of thermal expansion αfDensity G offAnd carrying out grid division on the model, adopting an Element Size division type, and setting an Element Size parameter as 5 e-3.
4. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1, wherein the method comprises the following steps: in the third step, the rotating speed of the blade in operation is 6000 rad/s.
5. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1, wherein the method comprises the following steps: in step S41, the elastic modulus, poisson' S ratio, thermal expansion coefficient and density of each layer of film material are obtained by measuring or looking up the table in S11, which is specifically shown in the following table;
6. the method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1, wherein the method comprises the following steps: in step S51, the turbine blade structure is composed of a blade body, a platform and a tenon, and includes a cooling hole and a cooling cavity structure inside; the film sensor is plated on the blade body and extends from the blade root to the blade tip; simplifying a turbine blade model to be modeled, simplifying a flange plate and a tenon into a block body with a cylindrical surface at the bottom, and recording the block body as the bottom of a blade; the blade body is simplified into a rectangular plate.
7. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1 or 6, wherein the method comprises the following steps: in step S51, the film sensor has a structure of substrate-transition layer-insulation layer-functional layer-protection layer, and the bottom transition layer is 1um NiCrAlY and 2um Al2O3Film, insulating layer of 2um Ta2O5And 2um SiO2The functional layer is 0.5um NiCr/NiSi film, and the protective layer is 4um SiO2A film.
8. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 7, wherein the method comprises the following steps: in step S51, in the simplified blade model, the blade body of the turbine blade is simplified into a rectangular parallelepiped structure with a size of 10cm × 2cm, a thickness of 1cm, and a size of the thin film sensor of 8cm × 1 cm; the thickness and parameters of each layer of film from bottom to top of the substrate are specifically shown in a S41 table, geometric modeling is completed, and material parameters in the table are defined; carrying out grid division on the model, thinning grids of a film part, adopting an Element Size division type for the 6-layer film part, and setting an Element Size parameter to be 5 e-4; binding contact is set between the substrate and the film and between the substrate and the film.
9. The method for simulating and calculating the coupling stress of the multilayer thin film under the action of the thermal-centrifugal load according to claim 1, wherein the method comprises the following steps: in step S62, the bottom cylindrical surface is applied at a rotation speed of 6000 rad/S.
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CN116502469A (en) * | 2023-06-25 | 2023-07-28 | 中国航发四川燃气涡轮研究院 | Turbine blade temperature correction method and device based on temperature test data |
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CN116502469A (en) * | 2023-06-25 | 2023-07-28 | 中国航发四川燃气涡轮研究院 | Turbine blade temperature correction method and device based on temperature test data |
CN116502469B (en) * | 2023-06-25 | 2023-09-05 | 中国航发四川燃气涡轮研究院 | Turbine blade temperature correction method and device based on temperature test data |
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