CN114951446B - Method for regulating and controlling electromagnetic impact composite forming of titanium alloy blade - Google Patents
Method for regulating and controlling electromagnetic impact composite forming of titanium alloy blade Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 99
- 229910001069 Ti alloy Inorganic materials 0.000 title claims abstract description 55
- 239000002131 composite material Substances 0.000 title claims abstract description 52
- 230000001105 regulatory effect Effects 0.000 title claims abstract description 17
- 230000001276 controlling effect Effects 0.000 title claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 67
- 230000008569 process Effects 0.000 claims abstract description 48
- 238000012545 processing Methods 0.000 claims abstract description 21
- 238000004513 sizing Methods 0.000 claims description 24
- 230000000694 effects Effects 0.000 claims description 19
- 239000011248 coating agent Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 13
- 238000005485 electric heating Methods 0.000 claims description 12
- 230000017525 heat dissipation Effects 0.000 claims description 11
- 230000001050 lubricating effect Effects 0.000 claims description 6
- 238000012546 transfer Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 4
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- 238000010248 power generation Methods 0.000 claims description 2
- 238000002474 experimental method Methods 0.000 claims 1
- 238000012937 correction Methods 0.000 abstract description 27
- 238000000137 annealing Methods 0.000 abstract description 20
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- 238000005242 forging Methods 0.000 abstract description 17
- 230000033228 biological regulation Effects 0.000 abstract description 14
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- 230000009471 action Effects 0.000 abstract description 5
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- 230000008878 coupling Effects 0.000 abstract 1
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
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- 229910052719 titanium Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/60—Making other particular articles cutlery wares; garden tools or the like
- B21D53/66—Making other particular articles cutlery wares; garden tools or the like spades; shovels
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C14/00—Alloys based on titanium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
- C22F1/18—High-melting or refractory metals or alloys based thereon
- C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon
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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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention relates to a method for regulating and controlling electromagnetic impact composite forming of a titanium alloy blade, which uses a special device with pressure maintaining and heat preserving functions and electromagnetic impact composite forming functions to perform near-constant temperature shape correction and mold-following heat treatment on the blade under the action of electromagnetic thermal coupling. The method can promote distorted lattice recovery and recrystallization of the forged blade, quickly eliminate forging residual stress, avoid deformation cracks, reduce tissue coarsening and thermal stress deformation in the blade annealing treatment process and effectively improve the blade production quality. The electromagnetic impact composite forming regulation and control device comprises electromagnetic impact composite processing equipment, temperature control equipment, pressure forming equipment and the like, and can apply adjustable electromagnetic thermal action to complete the thermal forming and thermal treatment process of the titanium alloy blade.
Description
Technical Field
The invention relates to the field of high-precision manufacturing and performance strengthening of titanium alloy components, in particular to a method for regulating and controlling electromagnetic impact composite forming of a titanium alloy blade.
Background
The titanium alloy has the advantages of high heat strength, good corrosion resistance, small heat conductivity coefficient and elastic modulus and the like, so the titanium alloy becomes an important structural material in the field of aerospace. The titanium alloy has low machinability and is difficult to form plastically at normal temperature, and hot forging is a main method for forming titanium alloy components, taking a titanium alloy aircraft blade as an example, and the precision forging process generally comprises the following steps: the method comprises the following steps of raw material inspection, rod extrusion heating, heading, pre-forging heating, final forging heating, edge cutting, shape correction heating, heat treatment, machining polishing, repairing, inspection and the like, wherein multiple blade surface treatment and quality inspection procedures are alternated in the period, and the total process flow is very fine and complex. Because the titanium alloy has large deformation resistance and is sensitive to deformation temperature, in the actual production process of the precision forging with the complex structure of the titanium alloy blade, the phenomena of part springback and distortion deformation often occur due to deformation residual stress and thermal stress generated in the repeated heating and cooling process, so that the process dimension deviation is caused, the control difficulty of the forging and forming process is large, and the yield is not high. After the blade is forged and formed, the forming precision is improved and the structure and the residual stress state are regulated and controlled by adopting a pressure sizing and long-time heat treatment method, the process is complex, the process parameter range is narrow, and new defects such as cracks, uneven structure and the like are easily caused by improper control.
Related patent "a method and device for correcting shape of blade by laser shot blasting" CN106270005A discloses a method and device for correcting shape of blade by laser shot blasting, which compares the actual size of the blade with the size of a CAD model by means of a three-dimensional profile scanner, determines laser shot blasting correction parameters and paths through data analysis, and uses high-power pulse laser shock wave to act on the surface of the blade to correct shape. The method needs to repeatedly compare digital models to adjust the shape correction parameters for multiple times of shape correction, the efficiency is difficult to guarantee, the shape correction effect of single-point or multi-point laser shot blasting on the blade with large curved surface size over-tolerance is limited, and repeated laser shot blasting treatment can also affect the surface quality of the blade.
Related patent "a titanium or titanium alloy electric pulse auxiliary hot stamping forming method and device" CN112246944A discloses a titanium or titanium alloy plate electric pulse auxiliary hot stamping forming method and device, and the titanium or titanium alloy part is obtained by placing the preheated plate on a cold die with an electric pulse processing tool for stamping forming. The method transfers the titanium alloy sheet with poor thermal conductivity to a cold forming die for forming, the thickness and the deformation of the sheet are not too large, otherwise, cracking is easy to occur in the rapid stamping forming process, the electrode arrangement form in the electric auxiliary forming device is not suitable for blade variable cross-section components due to the preference of a pulse current loop, a temperature control device is not adopted to control the thermal effect caused by pulse current, the hot forming structure of the titanium alloy blade is very sensitive to the temperature, once the local overheating phenomenon is caused, the regulation and control cannot be carried out by a heat treatment method, the repeated hot correction can also cause the structure to be thick, and the technical specification of the blade is not met.
Related patent "aeroengine blade sizing device and sizing method thereof" CN110421024A discloses an aeroengine blade cold sizing device and sizing method, the sizing method is more suitable for aluminum alloy blades with good plasticity, titanium alloy blades can generate larger elastic deformation in the cold sizing process, sizing cracks and residual stress can be caused, and more strict stress relief annealing and defect inspection are required after cold sizing, so the method and the device are difficult to ensure the quality and the efficiency of titanium alloy blade forming.
Related patent "mould and method for correcting complex titanium alloy machine-added part" CN111266462A discloses a mould and method for correcting titanium alloy machine-added part. According to the patent application, the method is characterized in that a boss is additionally arranged on an original titanium alloy forging blank for process positioning and auxiliary shape correction, an isothermal thermoforming press is used for heating and maintaining pressure of a machined forging to finish heat treatment and shape correction, and the boss is removed by milling after the shape correction is finished to obtain the accurate part. According to the method, the isothermal hot forming press is adopted to heat the part to the annealing heat treatment temperature, the efficiency is low, if the method is used for titanium alloy blade type curved surface components, the forging die and process parameters need to be adjusted by additionally arranging the lug boss, the original process is complicated, and the precision is affected by the fact that the part is deformed again due to milling of the lug boss after forming.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for regulating and controlling electromagnetic impact composite forming of a titanium alloy blade, which can improve the forming temperature uniformity of the blade, promote the distortion lattice recovery and recrystallization of the forged blade, quickly eliminate the forging residual stress, reduce the generation of deformation cracks, reduce the adverse effects of coarsening of the blade tissue, thermal stress deformation and the like caused by multiple heating in the conventional hot forming and heat treatment methods, and improve the forming precision and mechanical property of the blade.
The technical scheme adopted by the invention for solving the technical problems is as follows: the method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade comprises the following steps:
s1, placing a preheated blade blank into a lower die of a forming die for pressure forming, setting the die closing speed of a press machine to be multi-section, quickly completing a die closing idle stroke, switching to low-speed die closing when an upper die of the die is about to contact a blade, and performing pressure maintaining treatment after die closing operation is completed;
s2, in the process of pressure forming and pressure maintaining of the die, intermittent high-frequency pulse current is applied to the blade, the electric heating effect excited by the pulse current heats the preheated blade to a proper deformation temperature and offsets the heat dissipation capacity of the blade in the process, and the energy balance in the process meets the following formula:
ΔTCρdS+qFt＝I 2 Rt'
delta T is the difference value between the temperature of the blade measured by a temperature sensor and the set sizing temperature, C is the specific heat of the titanium alloy, rho is the density of the titanium alloy, d is the equivalent thickness of the blade, S is the equivalent sectional area of the pulse current passing through the blade, q is the equivalent heat transfer rate of the blade in the die and represents the heat dissipation quantity passing through the unit sectional area in unit time, F is the heat exchange area of the blade in the die, T is the total time of electromagnetic pulse processing, T' is the pulse current conduction time, I is the effective current of the pulse current excitation power generation heat effect, and R is the resistance value of the pulse current passing through the blade;
the electromagnetic impact processing process is divided into two stages, the first stage uses continuous high-frequency electromagnetic impact processing to enable the local temperature of the blade to quickly reach the thermal deformation temperature, the time consumption of the stage is short, the heat dissipation of the blade can be ignored, pulse current is set to be constant, electromagnetic impact processing is carried out, and the high-frequency electromagnetic impact processing time t required by the first stage is 1 The calculation process is as follows:
wherein rho' is the resistivity of the titanium alloy, and J is the current density of electromagnetic impact treatment;
when the temperature control equipment monitors that delta T is less than or equal to 10 ℃, the second stage of near constant temperature electromagnetic impact treatment is carried out, pulse current with constant parameters is applied to the blade, and the blade is enabled to be in a stable stateThe electric heating effect and the heat dissipation capacity of the blades are balanced; at a selected pulse current I and a single pulse duration t 2 In this case, the corresponding pulse frequency f is estimated in terms of maintaining the heat balance condition per unit time t:
s3, performing electromagnetic impact composite heat treatment; the press machine unloads or reduces the pressure keeping force when keeping the die closing state, heats the blade to the temperature range required by the heat treatment process of the titanium alloy blade through the combined heating synergistic effect of die preheating and electromagnetic impact, and maintains the isothermal state until finishing the heat treatment of the blade;
and S4, demolding and taking the workpiece.
According to the scheme, in the step S1, the pressure maintaining value is 10-50MPa, and the pressure maintaining time is 2-10min.
According to the scheme, the high-temperature lubricating coating with the electric conduction and anti-oxidation effects is uniformly coated on the surface of the blade blank.
According to the scheme, the upper die and the lower die are preheated before the step S1.
According to the scheme, a plurality of groups of pulse current loops with independently adjustable parameters are arranged in the forming die, and a plurality of groups of electrodes can synchronously apply electromagnetic impact treatment to the whole blade and can also independently perform electromagnetic impact treatment aiming at different deformation areas and stress concentration areas of the blade to regulate and control forming temperature and stress distribution.
The method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade has the following beneficial effects:
1. the method synchronously applies electromagnetic impact treatment in the pressure forming and heat treatment processes of the blade, promotes the distortion lattice recovery and recrystallization of the forged blade, eliminates forging residual stress, reduces the generation of deformation cracks, reduces adverse effects of coarsening of blade tissue, thermal stress deformation and the like caused by multiple heating in the conventional forming and heat treatment methods, and comprehensively improves the forming precision and mechanical property of the blade.
2. The invention can apply the coupled electromagnetic thermal action in the pressure forming and heat treatment processes of the blade, complete the heat forming and heat treatment in the same die, reduce the multiple transfer and repeated heating processes of the blade in the conventional blade manufacturing process and improve the production efficiency.
3. According to the invention, a plurality of groups of pulse current loops with independently adjustable parameters are designed in the forming die, and a plurality of groups of electrodes can synchronously apply electromagnetic impact treatment to the whole blade, and can also independently perform electromagnetic impact treatment aiming at different deformation areas and stress concentration areas of the blade, so that the forming temperature distribution is regulated and controlled, and the blade is prevented from forming larger tissue defects due to uneven forming temperature.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic view of the flow of regulation and control of the electromagnetic impact composite forming of the blade of the present invention;
FIG. 2 is a schematic view of an electromagnetic impact composite forming control device according to the present invention;
FIG. 3 is a schematic structural diagram of a mold of the electromagnetic impact composite shape correction and heat treatment device for the titanium alloy blade in the embodiment of the invention;
FIG. 4 is a schematic view of a lower mold of the electromagnetic impact composite shape-correction and heat-treatment apparatus in the embodiment of the present invention.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
The invention provides a method for regulating and controlling electromagnetic impact composite forming of a titanium alloy blade. The method combines the electromagnetic thermal action, can improve the forming temperature uniformity of the blade, promotes the distortion lattice recovery and recrystallization of the forged blade, quickly eliminates forging residual stress, reduces the generation of deformation cracks, reduces adverse effects of coarsening of blade tissue, thermal stress deformation and the like caused by multiple heating in the conventional hot forming and heat treatment method, and improves the forming precision and mechanical property of the blade. Compared with the common blade forming and heat treatment process, the electromagnetic impact composite forming regulation and control flow provided by the method is shown in the attached figure 1.
The electromagnetic impact composite forming regulation and control device provided by the invention can provide controllable electromagnetic thermal action for thermal forming and thermal treatment of the blade, improve the forming precision of the blade and regulate and control the organization and stress state of the blade. The device comprises a pressure forming device, a temperature control device and an electromagnetic impact processing device, wherein the pressure forming device comprises a press and a special die, and the die is provided with a porous structure design and is used for nesting and installing a pulse electrode, an electric heating pipe and a temperature sensor; the temperature control equipment consists of a plurality of electric heating pipes, a temperature sensor and a temperature controller, can set parameters such as heating temperature, heating rate and the like, and can cooperate with the electromagnetic impact processing equipment to control the temperature of the blade forming and heat treatment processes; the electromagnetic impact processing equipment consists of a plurality of groups of discharge electrodes, a voltage transformation frequency modulator and a pulse current controller, and can release high-frequency pulse current with adjustable parameters. The specific blade electromagnetic impact composite forming regulation and control device is shown in the attached figure 2.
The specific electromagnetic impact composite forming regulation and control method comprises the following steps:
step 1: and (6) detecting the blade forging stock. And (3) carrying out quality inspection and surface treatment on the blade forging blank, measuring the size out-of-tolerance condition of the blank relative to the blade, and batching according to subsequent different deformation quantities so as to select a forming die in a targeted manner and formulate electromagnetic impact composite forming and subsequent heat treatment parameters.
And 2, step: debugging and preheating the device. And selecting matched forming dies to be loaded into press equipment corresponding to different batches of blade blanks to be formed, connecting an electric heating pipe, a pulse electrode and a temperature sensor, and debugging the heating, die closing and pressure maintaining functions of the device. After the device is ensured to work normally, a conductive lubricating coating is coated on the die cavity, and the upper die and the lower die are preheated to 450-650 ℃ by an electric heating pipe in the temperature control device. In the subsequent deformation and heat treatment processes of the blank, the temperature control device can heat and preserve the temperature of the die again according to the difference condition of the process temperature and the monitored temperature, so that the overlarge temperature difference between the die and the blank is prevented.
And step 3: and (5) processing the blade blank. Uniformly coating a high-temperature lubricating coating with electric conduction and anti-oxidation effects on the surface of the blade blank, putting the blade blank into a heating furnace in batches according to the step 1 for preheating treatment, setting the preheating temperature by referring to the hot forging temperature of the corresponding titanium alloy, and setting the specific preheating time according to the thickness of the blade and the arrangement mode of the blade in the heating furnace.
And 4, step 4: and (4) pressure forming. And (4) transferring the preheated blade in the step (3) into a lower die of a preheating die, and performing pressure forming after ensuring the blade to be accurately positioned. The speed of the press machine for closing the dies is set to be multi-section, the idle stroke of closing the dies is completed quickly firstly, the heat dissipation time of the blade is reduced, and when the upper die of the die is about to contact the blade, the upper die of the die is changed into low-speed closing the dies (the strain rate can be 10 according to the size out-of-tolerance condition of the blade) -3 S to 10 -2 Adjusted in the range of/s) to avoid the generation of cracks at too fast a speed of blade deformation. And after the die assembly operation is finished, pressure maintaining treatment is carried out according to a certain pressure value and pressure maintaining time, the set range of the pressure maintaining value is 10-50MPa, the range of the pressure maintaining time is 2-10min, and the actual value is selected according to the out-of-tolerance condition of the blade size and the deformation resilience degree which can occur after forming.
And 5: and (4) performing electromagnetic impact composite forming. And 4, in the die pressure forming and pressure maintaining processes, applying intermittent high-frequency pulse current to the blade by the electromagnetic impact composite regulating and controlling device. The electromagnetic impact treatment equipment is a plurality of pulse current loops consisting of an inverter power supply with adjustable frequency f, a lead and a discharge electrode, and the size and the intermittent time of pulse current released by the electrode can be independently regulated according to the deformation condition of blades in an electrode arrangement area and temperature measurement data of a temperature sensor, so that the preheating blades can be heated to a proper deformation temperature by the electrothermal effect excited by the pulse current, and the heat dissipation capacity of the blades in the process is counteracted. The specific electromagnetic impact treatment process can be divided into two stages, wherein the first stage uses continuous high-frequency electromagnetic impact treatment to enable the local temperature of the blade to rapidly reach the thermal deformation temperature (which can be carried out in a plurality of times to avoid the occurrence of overtemperature). When the temperature control equipment monitors that the difference delta T between the temperature of the blade and the set forming temperature is less than or equal to 10 ℃, the second stage of near constant temperature electromagnetic impact treatment is carried out, pulse current with constant parameters is applied to the blade, and the electrothermal effect and the heat dissipation capacity of the blade are balanced. In the electromagnetic impact processing process, approximate electromagnetic impact processing parameters are calculated according to the thermal balance relation, and the magnitude and the frequency of the electromagnetic impact processing current can also be set to be automatically controlled by limiting the delta T value.
Step 6: electromagnetic impact composite heat treatment. After the electromagnetic impact composite forming of the blade in the step 4 and the step 5 is completed, the pressure maintaining force is unloaded or reduced by the press machine in a mold closing state, the blade is heated to a temperature range required by a heat treatment process by the synergistic action of mold preheating and electromagnetic impact composite heating by adopting the same method as the step 5, and the isothermal state is maintained until the heat treatment of the blade is completed.
And 7: and (5) demolding and taking the workpiece. After the heat treatment is finished, the blade can be taken out after the mold is slowly cooled, or the mold is opened and the blade is transferred to a specific environment for cooling so as to improve the production efficiency. (for titanium alloy blades needing double annealing, the blades can be transferred into a resistance furnace meeting the requirements to finish the second annealing according to batches because the second annealing temperature is low and the time is long.)
And 8: and (5) testing the quality of the blade. And (5) checking the dimensional accuracy, residual stress and structural state of the blade, and if the technical requirements of the blade can be met, repeating the steps 2 to 7 to finish the sizing and heat treatment of the batch of blades. And if the conditions of over-dimension, uneven structure or excessive residual stress still exist, changing the mould or adjusting the electromagnetic impact treatment parameters to repeat the steps 2 to 8 until the quality of the blade meets the technical requirements, and continuing the blade forming and heat treatment work of the batch.
Furthermore, for titanium alloy blades with the forming temperature and the heat treatment temperature close to each other, the electromagnetic impact composite forming temperature and the heat treatment temperature in the method can be set to be consistent, the process requirements are met by adjusting the pressure maintaining and heat preserving time, and the temperature impact possibly caused by adjusting the electric pulse parameters in the midway is avoided.
Furthermore, the temperature control equipment can determine whether to preheat the die according to specific conditions, and heat and preserve heat of the blade by cooperating with the electromagnetic impact equipment, so that the temperature parameter control in the blade forming and heat treatment processes is more stable. The die in the device is made of nickel-based high-temperature alloy, a plurality of cavities can be arranged, energy consumption is reduced, production efficiency is improved, and a demolding ejection mechanism or a V-shaped taper design is adopted, so that the blade can be quickly positioned and taken out of the die when being transferred.
Example 1: example of TA11 titanium alloy blade electromagnetic impact composite forming regulation and control method
A bar material meeting the technical requirements of TA11 titanium alloy blade production is forged and pressed into a curved blade according to process specifications, the blade with similar size over-tolerance is selected to test the size deviation and the surface residual stress of a specific position, and the shape correction and the heat treatment are respectively carried out according to the method and the conventional process method provided by the patent, so that the effects of different shape correction and heat treatment methods are compared. (TA 11 titanium alloy blade is manufactured by generally selecting 880-900 ℃ isothermal sizing, and then carrying out double annealing heat treatment, wherein 910 +/-10 ℃ multiplied by 1.5h +580 ℃ multiplied by 8 h.) according to the design size of the blade, processing a special die, and building a device required by electromagnetic impact composite sizing and heat treatment, wherein the die structure schematic diagram of the device for electromagnetic impact composite sizing and heat treatment of the blade is shown in an attached figure 3, and the lower die structure of the die is shown in an attached figure 4.
The specific shaping and heat treatment steps are as follows:
step 1, performing surface treatment and quality inspection on the forged blade, measuring the shape and position size of the blade, comparing the size with the design size, and formulating electromagnetic impact composite shape correction and heat treatment parameters. According to the technical requirements of TA11 titanium alloy blade manufacturing and multiple practical result analysis, the temperature of electromagnetic impact composite sizing is set to be 875 ℃, the double annealing treatment parameters are set to be 875 ℃ multiplied by 1h +580 ℃ multiplied by 8h, and the blade is switched into a resistance furnace for second annealing selection.
And 2, debugging and preheating the electromagnetic impact composite forming device. Selecting a hydraulic machine with the specification of 1600kN as pressure forming equipment, sequentially connecting an electric heating pipe, a pulse electrode and a temperature sensor (corresponding mounting holes are shown in figure 4) after a shape correcting die is installed, coating high-temperature insulating coating on the working surfaces of the upper die and the lower die, coating a conductive wear-resistant lubricating coating on the die cavity, and preheating the die to 680 ℃ by using the electric heating pipe after die assembly debugging.
And 3, preheating the blades. And (3) placing the blades into a resistance furnace at 850 ℃ for preheating treatment, wherein the preheating and heat preservation time is 10min.
And 4, quickly transferring the blade in the step 3 into a lower die of a preheating die, and executing die assembly operation after accurate positioning is ensured. The speed of a hollow stroke in the die closing process of the press machine is set to be 10mm/s, namely the speed is adjusted to be 0.1mm/s when the die is closed, pressure maintaining is carried out according to a 50kN pressure value after the die closing is finished, and the pressure maintaining time is set to be 3min.
And 5, in the low-speed mold closing and shape correcting process in the step 4, simultaneously applying pulse current to the blade by using an electromagnetic impact composite processing device with 9 pairs of electrode circuits. The pulse current output by each pair of electrodes is set to be 1200A, continuous electromagnetic impact treatment is applied for the first time to enable the blade to reach the shape correction temperature quickly, when the temperature rises to 870 ℃, pulse current treatment with the time length of 0.02s is applied for a single time, the frequency f of the pulse current is finely adjusted by practice, the temperature displayed by the temperature control device can be stabilized at 875 +/-3 ℃, and the blade annealing treatment stage is carried out after about 3min.
And 6: and (5) performing electromagnetic impact composite annealing treatment. After the shape correction is finished, the pressure maintaining pressure of the press is reduced in a die closing state, the pulse current applying frequency is reduced, and the blade is heated to 875 +/-1 ℃ and is kept warm for 1h by matching with a die heating system.
And 7: and (5) demolding and taking the workpiece. And (4) after the step 6 is finished, opening the die to take out the blade, and then putting the blade into a resistance furnace at 580 ℃ for annealing for 8 hours.
And (3) using the curved surface blades with similar size deviation, carrying out blade sizing and heat treatment according to a conventional method, and comparing the process effects. Cleaning a shape correction die cavity, preheating the die to 880 ℃, similarly preheating the blade to 880 ℃, repeating the step 3 and the step 4 to perform isothermal shape correction on the blade, then taking out the blade, and completing double annealing treatment by using a resistance furnace (910 ℃ multiplied by 1.5h +580 ℃ multiplied by 8 h).
After the steps are completed, the size out-of-tolerance condition, the surface residual stress value and the microstructure state of the blade in three states before blade processing, after the conventional method sizing and heat treatment and the electromagnetic impact composite forming regulation and control are compared. For the curved blade formed by forging and pressing under the same process conditions as a furnace batch, the warping condition of the blade can be effectively improved by a conventional method and an electromagnetic impact composite forming regulation and control method, the structural state and the mechanical property of the obtained blade meet the technical requirements of the TA11 titanium alloy compressor blade, and for the blade with larger correction deformation, fewer correction cracks occur after electromagnetic impact composite correction and heat treatment, and the surface residual stress test value is smaller.
Example 2: example of TC11 titanium alloy blade electromagnetic impact composite forming regulation and control method
A bar material meeting the technical requirements of TC11 titanium alloy blade production is forged and pressed into a curved blade according to process specifications, blades with similar size over-differential are selected to carry out electromagnetic impact composite shape correction and heat treatment with different process parameters, and the used device is the same as that in the embodiment 1. ( The TC11 titanium alloy blade is generally subjected to isothermal sizing at the temperature range of 860-900 ℃, and then subjected to double annealing heat treatment: 2h + at 950 +/-10 ℃ and 530 +/-10 ℃ and 6h. )
The specific electromagnetic impact composite forming regulation and control method comprises the following steps:
step 1, performing surface treatment and quality inspection on the forged blade, measuring the shape and position dimensions of the blade, comparing the shape and position dimensions with the design dimensions, and formulating electromagnetic impact composite shape correction and heat treatment parameters. According to the technical requirements of TC11 titanium alloy blade manufacturing and multiple practical result analysis, the lower sizing and annealing treatment temperature is finally selected, the electromagnetic impact composite sizing temperature parameter is set to be 850 ℃ multiplied by 4min, the first high-temperature annealing treatment parameter in the double heat treatment is set to be 940 ℃ multiplied by 1.8h, the blade is transferred into a resistance furnace for second annealing, and the parameter is set to be 530 ℃ multiplied by 6h.
And 2, debugging and preheating the shape correcting device. Selecting a hydraulic machine with the specification of 1600kN as pressure sizing equipment, installing a sizing die, sequentially connecting an electric heating pipe, a pulse electrode and a temperature sensor, coating high-temperature insulating coating on non-cavity working surfaces of an upper die and a lower die, coating a conductive wear-resistant lubricating coating on a cavity surface, and preheating the sizing die to 650 ℃ by using the electric heating pipe after die assembly debugging.
And 3, preheating the blades. And (3) putting the blades into a resistance furnace at 800 ℃ for preheating treatment, wherein the preheating and heat preservation time is 10min.
And 4, quickly transferring the preheated blade into a lower die of the preheating die, and executing die closing operation after accurate positioning is ensured. The speed of the mold closing idle stroke of the press machine is set to 10mm/s, namely the speed is reduced to 0.1mm/s when the mold is closed, pressure maintaining is carried out according to a 50kN pressure value after the mold closing is finished, and the pressure maintaining time is set to 4min.
And 5, in the low-speed die assembly and shape correction process in the step 4, applying electromagnetic impact treatment to the blade by using an electromagnetic impact composite regulation and control device with an electrode loop. The pulse current output by each pair of electrode loops is set to be 1200A, continuous electromagnetic impact treatment is applied for the first time to enable the blade to reach the shape correction temperature quickly, when the temperature rises to 845 ℃, pulse current treatment with the time length of 0.02s is applied for a single time, the frequency f of the pulse current is finely adjusted by practice, the temperature displayed by the temperature control device can be stabilized at 850 +/-3 ℃, and the blade annealing treatment stage is carried out after about 4min.
And 6: and (4) performing electromagnetic impact composite annealing treatment. After the shape correction is finished, the pressure maintaining pressure of the press is reduced in a die closing state, the pulse current applying frequency is reduced, and the blade is heated to 940 +/-1 ℃ and is kept warm for 1.8h by matching with a die heating system.
And 7: and (5) demolding and taking the workpiece. And (6) after the step 6 is finished, opening the die, taking out the blade for air cooling, and then transferring the blade into a resistance furnace at 530 ℃ for low-temperature annealing for 6 hours.
After the steps are completed, finished product inspection is carried out, and the electromagnetic impact composite forming regulation and control method used is proved to be capable of effectively correcting the size deviation of the TC11 blade, no shaping crack is detected on the blade, the residual stress on the surface and the internal part is effectively removed, and the structural state and the mechanical property of the blade can meet the technical requirements of the TC11 titanium alloy compressor blade.
While the present invention has been described with reference to the particular illustrative embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but is intended to cover various modifications, equivalent arrangements, and equivalents thereof, which may be made by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (5)
1. A method for regulating and controlling electromagnetic impact composite forming of a titanium alloy blade is characterized by comprising the following steps:
s1, putting a preheated blade blank into a lower die of a forming die for pressure forming, setting the die closing speed of a press machine to be multi-section, quickly completing a die closing idle stroke, switching to low-speed die closing when an upper die of the die is about to contact a blade, and performing pressure maintaining treatment after die closing operation is completed;
s2, in the process of pressure forming and pressure maintaining of the die, intermittent high-frequency pulse current is applied to the blade, the electric heating effect excited by the pulse current heats the preheated blade to a proper deformation temperature, the heat dissipation capacity of the blade in the process is counteracted, and the energy balance in the process meets the following formula:
ΔTCρdS+qFt＝I 2 Rt'
delta T is the difference value between the temperature of the blade measured by a temperature sensor and the set sizing temperature, C is the specific heat of the titanium alloy, rho is the density of the titanium alloy, d is the equivalent thickness of the blade, S is the equivalent sectional area of the pulse current passing through the blade, q is the equivalent heat transfer rate of the blade in the die and represents the heat dissipation quantity passing through the unit sectional area in unit time, F is the heat exchange area of the blade in the die, T is the total time of electromagnetic pulse processing, T' is the pulse current conduction time, I is the effective current of the pulse current excitation power generation heat effect, and R is the resistance value of the pulse current passing through the blade;
the electromagnetic impact processing process is divided into two stages, the first stage uses continuous high-frequency electromagnetic impact processing to enable the local temperature of the blade to quickly reach the thermal deformation temperature, the time consumption of the process is short, the heat dissipation of the blade can be neglected, the pulse current is set to be constant, and the high-frequency electromagnetic impact processing time t required by the first stage is set 1 The calculation process is as follows:
wherein rho' is the resistivity of the titanium alloy, and J is the current density of electromagnetic impact treatment;
when the temperature control equipment monitors that delta T is less than or equal to 10 ℃, the second stage of near constant temperature electromagnetic impact treatment is carried out, pulse current with constant parameters is applied to the blades, and the electric heating effect and the heat dissipation capacity of the blades are balanced; at a selected pulse current and a single pulse duration t 2 In this case, the corresponding pulse frequency f is estimated according to the heat balance condition maintained per unit time t:
the equivalent heat transfer rate q is a variable related to the appearance, material thermal conductivity and temperature difference factors of the blade and the die, and is obtained by adopting a mode of a blade cooling-along-die experiment;
s3, performing electromagnetic impact composite heat treatment; the press keeps a die closing state, unloads or reduces the pressure, heats the blade to a temperature range required by the heat treatment process of the titanium alloy blade through the combined heating synergistic effect of die preheating and electromagnetic impact, and maintains an isothermal state until the heat treatment of the blade is completed;
and S4, demolding and taking the workpiece.
2. The method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade according to claim 1, wherein in the step S1, the pressure maintaining value is 10 to 50MPa, and the pressure maintaining time is 2 to 10min.
3. The method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade as claimed in claim 1, wherein a high-temperature lubricating coating with electric conduction and anti-oxidation effects is uniformly coated on the surface of the blade blank.
4. The method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade according to claim 1, wherein the upper die and the lower die are preheated before the step S1.
5. The method for regulating and controlling the electromagnetic impact composite forming of the titanium alloy blade according to claim 1, wherein a plurality of groups of pulse current loops with independently adjustable parameters are arranged in a forming die, the pulse current loops are connected with pulse electrodes, the pulse electrodes are arranged in an upper die and a lower die, and the plurality of groups of pulse electrodes can synchronously apply electromagnetic impact treatment to the whole blade and can also perform electromagnetic impact treatment aiming at different deformation areas and stress concentration areas of the blade to regulate and control the forming temperature and the stress distribution state.
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