EP0700738B1 - Verfahren zur Herstellung einer hohlen Turbinenschaufel - Google Patents

Verfahren zur Herstellung einer hohlen Turbinenschaufel Download PDF

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Publication number
EP0700738B1
EP0700738B1 EP95402012A EP95402012A EP0700738B1 EP 0700738 B1 EP0700738 B1 EP 0700738B1 EP 95402012 A EP95402012 A EP 95402012A EP 95402012 A EP95402012 A EP 95402012A EP 0700738 B1 EP0700738 B1 EP 0700738B1
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EP
European Patent Office
Prior art keywords
manufacturing
stage
blade
blade according
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95402012A
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English (en)
French (fr)
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EP0700738A1 (de
Inventor
Matthieu Bichon
Yvon Marie Joseph Louesdon
Charles Jean Pierre Douguet
Florence Anne Nathalie Renou
Alain Georges Henri Lorieux
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
SNECMA SAS
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Application filed by Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA, SNECMA SAS filed Critical Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
Publication of EP0700738A1 publication Critical patent/EP0700738A1/de
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Publication of EP0700738B1 publication Critical patent/EP0700738B1/de
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Classifications

    • 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
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/053—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure characterised by the material of the blanks
    • B21D26/055—Blanks having super-plastic properties
    • 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
    • B21D53/78—Making other particular articles propeller blades; turbine blades
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49339—Hollow blade

Definitions

  • the present invention relates to a manufacturing process of a hollow turbomachine blade according to claim 1.
  • EP-A-0.500.458 describes a process for manufacturing a blade hollow for a turbomachine, in particular a rotor blade of large rope blower.
  • the primary parts used in this manufacturing include two outer sheets and at least one central plate.
  • the method described comprises a hot forming operation by bending and twisting the parts, a welding-diffusion operation in areas localized and a gas pressure inflation operation inducing a superplastic forming bringing the surfaces outside of dawn with the desired profile.
  • Tools suitable, in particular shape dies, are used for carrying out these operations.
  • the object of the invention is to provide the numerous methods known for making hollow blades, illustrated in particular by the example cited above, improvements notably aiming to obtain blades having improved mechanical characteristics and optimized in the conditions of use, guaranteeing repetitive quality while facilitating the conditions for manufacturing at the lowest cost.
  • the size of grain obtained is less than 10 ⁇ m, for a temperature forging the part between 880 ° C and 950 ° C and a tool temperature between 600 ° C and 850 ° C.
  • the bending / twisting of the blades placed after the welding-diffusion operation allows a more great ease of application of diffusion barriers on a preset pattern on a flat piece.
  • the production of a fan blade at very high compression ratio assumes very strong camber of the pale base and an accentuated twist and not continued. This requires a specific operation lengthening of the fibers preceding the twisting operation.
  • the twisting operation in this case can be integrated into the inflation operation under pressure gas and superplastic forming.
  • the cambering / twisting operation of the blades can be placed after the forging operation in the case of exploratory development requiring low parts series, or after the parts machining operation primary in the case of simple aerodynamic forms.
  • the cambering / twisting operation is carried out on a press, in an isothermal manner.
  • this temperature will be between 700 and 940 ° C.
  • This operation requires blocking the ends in order to guarantee effective fiber elongation in the areas chosen, this without tearing.
  • the length of the fiber central remains unchanged and the fiber elongation rate varies according to their distance to this central fiber.
  • the first step (a) of the process for manufacturing a hollow turbomachine fan blade according to the invention comprises a so-called flattening operation, from the definition of the finished part.
  • the flattening operation consists of deflation followed by defreezing / descaling.
  • the principles of construction and control of a fan blade are based on the use of defining sections distributed along the motor axis. Each section is worked so that all of the other constituent parts of the blade such as 11, 12 are pressed against the underside skin 13 unchanged. The thickness of the upper skin 11 is adjusted as a function of its subsequent elongation during the forming operation.
  • a digital simulation of the inflation is carried out confirming the intermediate result.
  • the final geometry twisted is transformed into the flat one.
  • the defreezing / descaling is a delicate operation for which the manufacturing process according to the invention provides a remarkable, automated method, respecting the conservation of the volume by the distribution of matter in function of the strain rate related to the position of each section.
  • the second step (b) consists in forging the parts on press constitutive primaries of dawn such as 11, 12, 13 visible in Figure 9, by stamping. According to the techniques known in the past, this type of part is made from of rolled sheets because it is considered that the dimension and the size does not allow to ensure by forging a blank sufficiently precise and fine.
  • the starting blank consists, as shown in Figure 2, of a bar 3, of a titanium alloy for example TA6V, of dimension adequate (diameter between 80 and 120mm) to achieve the draft of the primary parts.
  • a bar 3 of a titanium alloy for example TA6V of dimension adequate (diameter between 80 and 120mm) to achieve the draft of the primary parts.
  • one or more upsetting operations allow placement of the material in high volume areas type 4 foot or blade tip.
  • the bars are heated to a temperature between 880 ° C and 950 ° C, while the tool is heated to a temperature between 200 and 250 ° C.
  • One of the difficulties and therefore a remarkable stage in process according to the invention resides in the ability to produce forged blanks 5 as shown in the figure 5 of dimension and especially thickness capable of producing economically long-rope blades.
  • the inventors have developed a method of forging blanks allowing to guarantee blanks on a high power press precise and calibrated.
  • the inventors have developed a process comprising a judicious combination of a form trapezoidal 6 of the blank 5 as shown in the Figure 4, lubrication and heating of tools.
  • the forging operation on a press or forging making it possible to obtain the parts such as 5 of FIG. 4 is done by heating the room to a temperature between 880 ° C and 950 ° C and the tooling at a temperature between 700 ° C and 900 ° C.
  • Figure 7 shows a graph temperature evolution at each stamping.
  • the curve a corresponds to the temperatures of the contact surfaces of matrix
  • curve b the internal temperature of the tool
  • curve c the temperature of the tool holder.
  • the structure of the start bars 3 is rough by compared to conventional specifications applied to bars smaller dimensions (diameter 50 mm) used for the Forging of conventional turbojet blades: forging and matrixing make it possible to refine the structure in a way significant since the grain size is reduced by 10 ⁇ m on average at 7 ⁇ m. This operation thus saves 30 MPa on average on the fatigue strength of the final product and this despite the thermal cycles of welding-diffusion and inflation following the forging operation.
  • the precision forging makes it possible to make the surface 8 left external finished forging: the final surface condition being obtained by selective polishing, with numerical control, performed on a 5-axis polishing machine.
  • the finish of the internal surface 9 of the primary parts is produced by machining by any machining process known per se, these machining operations constituting step (C) of the process in accordance with the invention.
  • stages (f) of inflation under gas pressure and superplastic forming and (g) final machining are then carried out under production conditions known per se, parameters, including temperature and pressures applied being determined according to the material of the rooms. Furthermore and depending on the application of the process according to the invention, in particular for obtaining fan blades, a shaping of the parts by camber / twist is required. In this case the bending / twisting is a delicate operation which requires a a number of precautions to avoid the occurrence undulations due to the lengthening of the different parts of the part during this operation.
  • the operation consists of isothermal shaping of the primary part or of the welded assembly, in a press at a temperature between 700 and 940 ° C. allowing, with a tool 21, to obtain the elongations of the different fibers of the Exhibit 19.
  • This operation is carried out at controlled pressure between two metal or ceramic tools at the same temperature as the part is 700 ° C to 940 ° C.
  • the geometric definition of tool 21 produced in CAD / CAM integrates the shape of the part massive foot 22 and laterally the progressive elongations fibers in particular by one or more waves 23, 24, 25, 26 whose amplitude varies with the rate of elongation necessary, as shown diagrammatically in Figures 13 and 14.
  • This operation can include the arching of the foot 22.
  • the addition of extra thicknesses 28, 29, 30 judiciously placed provides support from the first contact workpiece / tool, as shown in figure 15.
  • the welded assembly 31 is maintained at each end by two jaws 32, 33 at least one of which is movable in rotation.
  • the twisting operation is carried out in an oven or heating chamber, at a creep temperature included between 880 ° C and 920 ° C depending on the alloy of the assembly welded.
  • another method is to provide the rotational movement of at least one jaw by a system mechanical acting on the lever arm 37, this is then made by two fingers fixed on the movable part of a press to which a local heating chamber is added 38.
  • Added local footprints 36 provide the accentuated aerodynamic shape of the trailing edge.
  • one of the jaws can be equipped with a helical coupling in order to apply a tensile stress during twisting, allowing avoid the appearance of a ripple phenomenon, so remarkable, in accordance with the invention.
  • the super plastic forming operation is carried out between 850 and 940 ° C under a pressure of 20 to 40x10 5 MPa of argon.
  • the blade 31 at from the geometry obtained after elongation of the fibers in the same operation as the inflation.
  • the decrease in number of heaters promotes the conservation of high mechanical properties obtained by forging constituent parts of dawn.

Claims (15)

  1. Verfahren zur Herstellung einer hohlen Turbinenschaufel, insbesondere einer Gebläserotorschaufel mit großer Weite, bestehend aus den folgenden Verfahrensschritten:
    a) ausgehend von der Definition einer herzustellenden Schaufel erfolgt die Entwicklung unter Verwendung von Mitteln zum rechnerunterstützten Entwerfen (CAD) und zur rechnergestützten Fabrikation (CAM) sowie die Herstellung einer numerischen Simulation des Flachformens der Bestandteile der Schaufel,
    b) Schmieden der Rohlinge durch Hohlprägen auf der Presse,
    c) Bearbeitung der Rohlinge,
    d) Aufbringen von Diffusionswänden nach einem vorbestimmten Muster,
    e) Zusammensetzen der Rohlinge, gefolgt von dem Vorgang des Diffusionsschweißens unter isostatischem Druck,
    f) Aufblähen unter Gasdruck und superplastisches Formen,
    g) Endbearbeitung, bei der in Schritt b) das Hohlprägen mit Warmmatrize bei einer Temperatur von 0,7 bis 0,8 Tf ausgeführt wird, wobei Tf die Schmelztemperatur des Materials ist, wobei die Temperatur der Werkzeuge auf 80 % der Temperatur des Werkstücks gebracht wird, ferner das verwendete Rohteil eine spezielle Trapezform dergestalt aufweist, daß ein Endprodukt mit einer geringen Stärke erzielt wird, die das 0,02-fache der Schaufelbreite beträgt, und daß ein Raffinieren des Metalls erreicht wird, durch das eine geeignete Körnung garantiert werden kann, die in dem Schritt e) gute Bedingungen für das Diffüsionsschweißen gewährleistet sowie die gewünschten mechanischen Eigenschaften gewährleistet, damit die fertige Schaufel ein günstiges Materialermüdungsverhalten aufweist, wobei das Verfahren einen zusätzlichen Schritt des Hohlprägens und Verwindens enthält, wodurch ein Dehnen der Fasern des Materials der Werkstücke bewirkt wird, so daß die neutrale Faser zu beiden Seiten der Achse (20) des Werkstücks auf die Endlänge gebracht werden kann, wenn die Dicke der Werkstücke in Verbindung mit dem Verformungsgrad unter der Knickgrenze liegt.
  2. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 1, wobei der Schritt a) eine numerische Simulation eines Entbläh-Vorgangs beinhaltet, wobei die anderen Bestandteile (11, 12) der Schaufel auf der unveränderten Druckseiten-Außenschicht (13) angebracht werden.
  3. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 2, wobei die numerische Simulation durch ein Aufdrehen/Geradebiegen dergestalt erfolgt, daß ein flaches Produkt (2) erzielt wird.
  4. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 1, wobei der Schritt a) eine numerische Simulation des vollkommenen Flachformens (2) in einem einzigen Arbeitsvorgang, berechnet auf Basis der verwundenen Endgeometrie der Schaufel (1), beinhaltet.
  5. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 4, wobei die genannte Schaufel aus einer Titanlegierung des Typs TA6V besteht, die Prägetemperatur der Werkstücke zwischen 880°C und 950°C beträgt, die Temperatur der Werkzeuge zwischen 600°C und 850°C beträgt und der Prägevorgang es erlaubt, eine metallurgische Mikrostruktur des Werkstücks mit einer Körnung von weniger als 10 µm zu erzielen.
  6. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 5, wobei der zusätzliche Schritt (e1) des Hohlprägens und Verwindens nach dem Diffüsionsschweißvorgang (e) erfolgt.
  7. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 5, wobei ein Vorgang des Dehnens der Fasern nach dem Arbeitsschritt (e) des Diffusionsschweißens und in dem Arbeitsschritt (f) erfolgt, wobei der Vorgang des Verwindens in den Vorgang des Auftreibens unter Gasdruck und superplastischen Formens integriert ist.
  8. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 5, wobei der zusätzliche Schritt des Hohlprägens und Verwindens nach dem Arbeitsschritt (b) des Schmiedens der Rohlinge erfolgt.
  9. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 5, wobei ein zusätzlicher Schritt des Hohlprägens und Verwindens nach dem Arbeitsschritt (c) der Bearbeitung der Rohlinge erfolgt.
  10. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 1 bis 6, wobei der zusätzliche Schritt des Hohlprägens und Verwindens isothermisch auf einer Presse erfolgt.
  11. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 10, wobei die genannte Schaufel aus einer Titanlegierung des Typs TA6V besteht und die Isothermschmiede-Temperatur beim Vorgang des Hohlprägens und Verwindens zwischen 700°C und 940°C beträgt.
  12. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 10 oder 11, wobei beim Vorgang des Hohlprägens und Verwindens ein Blockieren von mindestens zwei Werkstückenden gewährleistet wird, um in den gewählten Bereichen eine effektive Dehnung der Fasern zu garantieren, wobei der Dehnungsgrad der Fasern je nach ihrem Abstand zu einer Achsfaser des Werkstücks, deren Länge unverändert bleibt, unterschiedlich ist.
  13. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 12, wobei beim Vorgang des Verwindens die zuvor gedehnten Fasern durch lokal begrenzte Formwerkzeugteile (36) dergestalt umgeformt werden, daß in einem gewählten Bereich eine betonte aerodynamische Form entsteht.
  14. Verfahren zur Herstellung einer hohlen Schaufel nach einem der Ansprüche 12 oder 13, wobei beim Vorgang des Verwindens das System zum Blockieren von mindestens einem der Werkstückenden eine Vorrichtung aufweist, mit der auf das Werkstück in der Achse des Werkstücks eine Drehung und ein Zug ausgeübt werden kann.
  15. Verfahren zur Herstellung einer hohlen Schaufel nach Anspruch 1, wobei nach dem Verfahrensschritt (b) ein zusätzlicher Schritt (b1) erfolgt, der einen Vorgang des Formens auf der Presse beinhaltet.
EP95402012A 1994-09-07 1995-09-06 Verfahren zur Herstellung einer hohlen Turbinenschaufel Expired - Lifetime EP0700738B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9410690A FR2724127B1 (fr) 1994-09-07 1994-09-07 Procede de fabrication d'une aube creuse de turbomachine
FR9410690 1994-09-07

Publications (2)

Publication Number Publication Date
EP0700738A1 EP0700738A1 (de) 1996-03-13
EP0700738B1 true EP0700738B1 (de) 1999-12-08

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EP95402012A Expired - Lifetime EP0700738B1 (de) 1994-09-07 1995-09-06 Verfahren zur Herstellung einer hohlen Turbinenschaufel

Country Status (9)

Country Link
US (1) US5636440A (de)
EP (1) EP0700738B1 (de)
JP (1) JP3305927B2 (de)
AT (1) ATE187370T1 (de)
CA (1) CA2157643C (de)
DE (1) DE69513754T2 (de)
ES (1) ES2139860T3 (de)
FR (1) FR2724127B1 (de)
IL (1) IL115123A (de)

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FR2978926B1 (fr) * 2011-08-11 2014-05-09 Snecma Dispositif pour la mise en forme d'une tole par matricage
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CN107838642B (zh) * 2017-12-18 2019-03-05 中国航发贵州黎阳航空动力有限公司 一种双轴颈薄壁叶片零件的加工方法
CN108372391A (zh) * 2018-03-05 2018-08-07 广汉天空动力机械有限责任公司 一种涡轮转子空心叶片的制造方法
US11148221B2 (en) * 2019-08-29 2021-10-19 Raytheon Technologies Corporation Method of forming gas turbine engine components
CN115570105B (zh) * 2022-11-21 2023-05-05 中国航发四川燃气涡轮研究院 一种双层壁涡轮叶片的制造方法

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JPH08189303A (ja) 1996-07-23
US5636440A (en) 1997-06-10
JP3305927B2 (ja) 2002-07-24
FR2724127A1 (fr) 1996-03-08
IL115123A0 (en) 1995-12-31
IL115123A (en) 1999-11-30
DE69513754D1 (de) 2000-01-13
DE69513754T2 (de) 2000-06-29
ES2139860T3 (es) 2000-02-16
EP0700738A1 (de) 1996-03-13
CA2157643A1 (fr) 1996-03-08
FR2724127B1 (fr) 1996-12-20
ATE187370T1 (de) 1999-12-15
CA2157643C (fr) 2004-11-23

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