EP1629906A1 - Verfahren zur Herstellung der Bestandteilen einer Hohlen Gebläseschaufel durch Schmieden - Google Patents

Verfahren zur Herstellung der Bestandteilen einer Hohlen Gebläseschaufel durch Schmieden Download PDF

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Publication number
EP1629906A1
EP1629906A1 EP05107652A EP05107652A EP1629906A1 EP 1629906 A1 EP1629906 A1 EP 1629906A1 EP 05107652 A EP05107652 A EP 05107652A EP 05107652 A EP05107652 A EP 05107652A EP 1629906 A1 EP1629906 A1 EP 1629906A1
Authority
EP
European Patent Office
Prior art keywords
primary
forging
blank
blade
parts
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.)
Withdrawn
Application number
EP05107652A
Other languages
English (en)
French (fr)
Inventor
Christine Deron
Alain Georges Henri René LORIEUX
Philippe René Georges JOFFROY
Jean-Louis Paul Victor Despreaux
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
SNECMA Moteurs SA
SNECMA SAS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by SNECMA Moteurs SA, SNECMA SAS filed Critical SNECMA Moteurs SA
Publication of EP1629906A1 publication Critical patent/EP1629906A1/de
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K3/00—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like
    • B21K3/04—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like blades, e.g. for turbines; Upsetting of blade roots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/008—Incremental forging
    • 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
    • Y10T29/4932—Turbomachine 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
    • 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 generally to the field of turbomachine blade manufacturing processes, such as hollow fan blades, or any other type of rotor blades or turbomachine stator or propellant.
  • a hollow fan blade for a turbomachine comprises a foot of relatively large thickness for fixing the blade in a rotor disk, this foot being extended radially outwards by a thin aerodynamic portion, called blade of the blade. dawn.
  • the previously manufactured preform is aerodynamically profiled, then inflated by gas pressure and superplastically formed into this preform, in order to produce a blade having substantially its final shape which undergoes a final machining.
  • the manufacture of the blade preform requires a step of producing at least two external parts.
  • the manufacture of external parts is typically done by machining supply elements.
  • Each of the two machined outer parts has two radially opposite portions of very different thicknesses: the thick foot part serves to fix the blade in the rotor disk, and the pale, aerodynamic and thin portion extends to from the foot part to the radially outer end.
  • US-A-5,711,068 discloses a method of producing generally parallelepiped-shaped pieces of metallic material longer than the length of the preform from the foot portion to the blade portion and having a thickness close to that of this foot part. Each parallelepiped is then cut in an oblique direction to form two separate panels of thickness flaring longitudinally. Complex to implement, this method quickly finds limits in terms of the maximum thickness that can be obtained, and additional elements are conventionally added to form the foot of the blade.
  • US-A-5,636,440 discloses a forging technique of a metal bar in which a pushing allowed the introduction of material in a high volume area for manufacturing the foot. The forged bar in the primary part is then machined. Nevertheless, this embodiment is limited by the power of the existing production means, in particular for external primary parts intended for the manufacture of large blades.
  • the manufacture of external parts intended to form at least partially the blade preform therefore leads to a use of material with losses, which can generate significant costs, and delicate machining techniques, so that this method of manufacturing the hollow blade is not fully optimized.
  • the object of the invention is to propose a method of manufacturing a hollow turbine engine blade, at least partially overcoming the disadvantages mentioned above.
  • the invention relates to a method of manufacturing a hollow blade whose step of producing the external parts of the blade preform allows the manufacture of blades of large dimensions minimizing the material losses and using more or less conventional and proven machining, which allows among others not to increase manufacturing costs significantly compared to those encountered in the prior art.
  • the invention relates to a method of manufacturing primary parts using die forging.
  • this forging is carried out in at least two successive complementary steps with regard to the finishing forging, that is to say the forging which results in the production of the primary part itself.
  • the primary part produced by the process according to the invention may have a general shape of a thickness-to-width ratio plate of less than 0.03 or even 0.025.
  • Forging is preferably carried out from a bar, with intermediate manufacture of a blank whose section is optimized for the power of the press.
  • each forging step is performed by a mechanical press.
  • the manufacture of the primary parts is incorporated in a process for manufacturing a hollow turbine engine blade, comprising a foot and a blade, and preferably made by diffusion bonding and superplastic forming.
  • the invention in another aspect, relates to a set of dies suitable for forging a matrix in several strokes of a primary part, comprising at least a first die of which only a part has a shape complementary to the primary part, the other part corresponding to to the initial draft, and a second matrix corresponding to the primary part itself.
  • the connection zone between the two parts of the first die is set to obtain an optimal primary part, not requiring intense machining and / or not causing excessive loss of material.
  • FIG. 1 represents a hollow blade 1, of the large-rope fan rotor blade type, for a turbomachine (not shown).
  • a blade made for example of titanium or one of its alloys such as TA6V, has a foot 2 extended by a blade 4 in a radial direction.
  • the blade 4 intended to be placed in the flow channel of an air flow of a turbomachine, is provided with two outer surfaces, respectively called extrados surface 6 and intrados surface 8, connected by an edge 10 and a trailing edge 12.
  • a hollow blade In order to manufacture such a complex profile, it is preferable for a hollow blade to use the Superplastic Forming / Diffusion Bonding (SPF / DB) process.
  • SPF / DB Superplastic Forming / Diffusion Bonding
  • the first step is to model the profile of the blade 1 to obtain a preform that can be made by welding primary parts: the intrados 8 and extrados 6, or their graphical representation, are plated on the same plane.
  • This operation can be performed by simulation, using CAD (computer-aided design) means, for example comprising a deflation followed by a unscrewing and a "Décambrage", which provides a preform 14 as shown in Figure 2.
  • CAD computer-aided design
  • This preform 14, of length L and average width 1 comprises a foot portion 16 which is extended in a radial direction by a blade portion 18. As can be seen in this FIG. 2, the foot portion 16 has an internal portion. 20 of high average thickness 2H, which is subsequently intended to ensure the attachment of the blade in a rotor disk of the turbomachine.
  • the blade portion 18 of the preform 14 has a radially inner end 22 of a thickness 2e and a radially outer end 24 of a thickness 2e ', generally lower than the thickness 2e.
  • the blade portion 18 of the preform 14 is of substantially homogeneous thickness along its length L.
  • the preform 14 (which, for a hollow blade 1, must be "inflated” so can not consist of a single block), primary parts that will be secured are defined. It is possible to define the primary parts in different ways from the block 14, the most immediate being a longitudinal section along the axis AA, to form at least two external primary parts 26, 28.
  • the primary parts 26, 28 thus defined have a complex profile, in particular with a foot portion of thickness H and a long blade portion whose thickness varies from e to e '.
  • US-A-5,636,440 discloses such a technique, shown diagrammatically in FIGS. 3: a bar 30 of adequate dimensions for producing the primary parts 26 undergoes upsetting operations (FIG. 3B) allowing the introduction of material into areas of high volume 32 for example to form the foot portion 16 of the primary part 26. Then forging the pushed bar 30b provides the primary part itself.
  • the press first forms a blank 34 from a first die (forging of the blank , or "first strike", Figure 3C), which allows to distribute the material so as to limit the final forging force.
  • the "finishing forging” (FIG. 3D) with a second matrix makes it possible to obtain a substantially flat primary part 26 on each surface and which can then be machined for shaping the blade, for example by SPF / DB.
  • the dies correspond to the shape of the pieces obtained, that is to say are of complementary shape to the blank 34 or to the primary piece 26.
  • the die forging technique finds its limits because the dimensions of the primary parts can be doubled for example. As the thickness remains low, particularly less than one centimeter, the thickness-to-width ratio of the primary parts becomes too great: the forging force then requires a power incompatible with economic profitability. In fact, the mechanical presses that would be required are sometimes not even on the market.
  • mechanical presses power 16 000 t are already exceptions and only very few copies are currently available in the world. It does not seem materially or economically feasible to design a mechanical press with a very superior power and capable of producing the aforementioned parts.
  • Hydraulic presses can certainly bring the required power; however, they are slow (of the order of 10 s for matrix forging), which involves cooling the material to be forged, and would require the use of hot matrices. The cost here again becomes prohibitive.
  • the invention provides a method in which the outer primary piece is forged into several finishing operations by forging into separate dies.
  • the primary part may correspond to the modeling carried out at first glance, for example by CAD, and the initial masses of material involved are reduced, as are the machining operations.
  • forging processes that are industrially proven, and in particular presses already used, can be used, which limits the costs.
  • Finishing operations are performed by complementary die forgings, ie each part of the primary piece is subjected to forging pressure once for finishing, but several steps are required to forge the different parts.
  • the primary part resulting from the method according to the invention does not require significant additional machining for finishing its surface relative to a primary part made in a striking.
  • the primary part 40 comprises a second protuberance 46 at its other end relative to the foot part 48.
  • This protuberance 46 makes it possible to limit the longitudinal expansion during the forging phase; it is preferably of less volume than the foot portion 48 and can be easily removed during the final machining.
  • the primary part 40 is substantially in the form of a flat plate, for at least 80% or even 90% of its surface.
  • the primary part 40 ' may have a complex surface shape, for example a saber shape, and the protuberance 46' may be located in the first portion 42 '.
  • the portions 42 ', 44' are not necessarily defined perpendicular to the length L.
  • a bar of a titanium alloy such as TiAlv the dimensions of which are suitable for roughing the primary part 40, for example a bar 30 of diameter 100 mm and length 1200 mm.
  • the bars or their derivatives such as the blanks are heated to a temperature of between 880 ° C. and 950 ° C., and the shaping tool is heated to a temperature of between 200 ° C. and 300 ° C.
  • One or more conventional upsetting operations allow the introduction of additional material in high volume areas.
  • the upsetting operations can thus create two high-volume zones, for the protuberance 46 and the foot portion 48.
  • a matrix forging step of the blank 50 shown schematically in FIGS. 5A and 5B is carried out.
  • the blank 50 is formed with cross-sections of trapezoidal or hexagonal shape as shown: in fact, the friction forces are then minimal and the dimensions Le, the obtained with respect to the average thickness are optimal. Another possibility concerns ovoid sections.
  • the matrix used at this stage has, as is known, a shape complementary to the shape of the blank 50, and is manufactured according to a conventional method.
  • the dimensions of the matrix are parameterized so as to use the maximum power of the press that is envisaged to use: length, width and thickness e, E are as close as possible to the dimensions of the primary part 40, while not exceeding the capacities of the press.
  • the blank 50 is then forged a first time, by means of a first die defined to produce first strike an intermediate piece 52 (or intermediate blank) shown in Figure 6A comprising a first portion corresponding to the first portion 42 of the primary part 40, with for example the foot part 48, and a second portion 54 corresponding to the blank which is not modified and is intended to be the second portion 44 of the primary part 40.
  • the first matrix 60 schematized FIG. 6B thus comprises a first part 62 of shape complementary to the first portion 42 of the primary part 40, and a second part 64 complementary to the unmodified part of the blank 54, that is to say similar to the matrix used for rough forging 50.
  • the dimensions of the first portion 62 may be defined so that the forged surface (first portion 42 of the primary piece) c corresponds to the maximum power of the press used.
  • a second strike consists in forging the portion left in the blank 54, in order to obtain at the end of this finishing forging a primary piece 40 as predefined, and whose thickness / width ratio is such that the material used and the Final machining for dawn is reduced.
  • the matrix used for this step corresponds to the final piece 40.
  • the finishing dies 60 except the last which corresponds to the primary part, thus comprise a first part 62 whose shape is complementary to the primary part 40 (that is to say flat except for the foot part 48). and the reinforcement protrusion 46) and on which the pressure will be exerted, and a second portion 64 corresponding to the blank 50, of shape for example ovoid or trapezoidal, which will not transmit the forces of the press to the metal of the forged part.
  • a connecting zone 66 whose profile is determined so as to allow during the next strike a connection "smooth" or without burr between the different portions 42, 44 of the primary part 40, so as to minimize the machining costs.
  • connection zone 66 is schematized in FIGS. 6B and 6C: surprisingly, calculations and experiments have shown that the connection zone 66 between a trapezoidal or hexagonal blank section 64 and a finely shaped portion flat plate 42 is linear in both thickness and width, or forms a gradient.
  • first and second portions 42, 44 of the primary part 40 each represent a half in the longitudinal direction
  • other configurations are possible.
  • matrix configurations shown in FIG. conceivable.
  • three matrices can be considered for three finishing strikes.
  • the external primary parts 26, 28 are assembled into a preform 14 and secured, possibly, depending on the size of the blade, the stresses that will be applied to it, ... with a primary holding part substantially in the form of sheet inserted between them and intended to stiffen the hollow structure.
  • the parts are assembled by diffusion welding.
  • the preform 14, possibly aerodynamically profiled, is machined to obtain a blade 1.
  • this step is performed by gas pressure inflation and superplastic forming, according to the conditions known in the SPF / DB technique.
  • the method according to the invention makes it possible to use an existing press to manufacture a plate of larger dimensions, for example twice, than those authorized by the nominal power of the press.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
EP05107652A 2004-08-23 2005-08-19 Verfahren zur Herstellung der Bestandteilen einer Hohlen Gebläseschaufel durch Schmieden Withdrawn EP1629906A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0451885A FR2874339B1 (fr) 2004-08-23 2004-08-23 Procede de fabrication de pieces constitutives d'une aube creuse par forage sur presse

Publications (1)

Publication Number Publication Date
EP1629906A1 true EP1629906A1 (de) 2006-03-01

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EP05107652A Withdrawn EP1629906A1 (de) 2004-08-23 2005-08-19 Verfahren zur Herstellung der Bestandteilen einer Hohlen Gebläseschaufel durch Schmieden

Country Status (5)

Country Link
US (1) US8683689B2 (de)
EP (1) EP1629906A1 (de)
CN (1) CN1721129A (de)
FR (1) FR2874339B1 (de)
RU (1) RU2383408C2 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101773972A (zh) * 2010-02-25 2010-07-14 无锡透平叶片有限公司 一种高强铝合金坯料的制坯工艺
CN102836946A (zh) * 2012-09-11 2012-12-26 四川豪特石油设备有限公司 600mw机组汽轮机末级动叶片辊锻成形工艺
EP2924244A4 (de) * 2012-12-19 2016-03-09 Mitsubishi Hitachi Power Sys Verfahren zur herstellung eines turbinenrotorblatts
WO2021116086A1 (fr) * 2019-12-09 2021-06-17 Safran Aero Boosters Sa Procédé de fabrication d'une aube de compresseur

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CN100424193C (zh) * 2006-02-09 2008-10-08 沈阳黎明航空发动机(集团)有限责任公司 Gh696合金叶片形变热处理成形工艺
DE102008017624A1 (de) * 2008-04-04 2009-10-08 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur aerodynamischen Ausformung der Vorderkante von Bliskschaufeln
JP2010196583A (ja) * 2009-02-25 2010-09-09 Ihi Corp ノズルベーンの製造方法
US8485787B2 (en) * 2009-09-08 2013-07-16 Siemens Energy, Inc. Turbine airfoil fabricated from tapered extrusions
RU2463125C2 (ru) * 2011-01-11 2012-10-10 Открытое Акционерное Общество "Корпорация Всмпо-Ависма" Способ изготовления заготовок широкохордных пустотелых лопаток вентилятора газотурбинного двигателя
GB201707896D0 (en) * 2017-05-17 2017-06-28 Rolls Royce Plc Forging apparatus and method
CN108817867B (zh) * 2018-08-20 2021-03-05 中国航空制造技术研究院 一种密闭带筋空心构件的成形方法
JP7253995B2 (ja) * 2019-07-24 2023-04-07 株式会社日立製作所 製造工程設計方法及び製造工程設計システム
CN112275971B (zh) * 2020-08-31 2022-08-26 中国航发南方工业有限公司 钛合金偏心变截面叶片的聚料工装及锻造方法

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JPH0280149A (ja) * 1988-09-16 1990-03-20 Agency Of Ind Science & Technol タービンブレードの鍛造プリフォームの成形方法及び成形金型
US5636440A (en) 1994-09-07 1997-06-10 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Process for manufacturing a hollow blade for a turbo-machine
US5711068A (en) 1995-10-28 1998-01-27 Rolls-Royce Plc Method of manufacturing a blade

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US4620660A (en) * 1985-01-24 1986-11-04 Turner William C Method of manufacturing an internally clad tubular product
FR2626507A1 (fr) * 1988-02-03 1989-08-04 Snecma Procede de fabrication d'ebauches forgees en barre par refoulage, notamment pour aubes de compresseur et outillage de mise en oeuvre
FR2739045B1 (fr) * 1995-09-27 1997-10-31 Snecma Procede de fabrication d'une aube creuse de turbomachine
FR2749784B1 (fr) * 1996-06-13 1998-07-31 Snecma Procede de fabrication d'un aube creuse de turbomachine et presse-four a multiple effet utilisee dans sa mise en oeuvre
FR2752539B1 (fr) * 1996-08-22 1998-09-18 Snecma Procede de fabrication d'une aube creuse de turbomachine et equipement de vrillage evolutif a chaud utilise
GB9924219D0 (en) * 1999-10-14 1999-12-15 Rolls Royce Plc A method of manufacturing an article by superplastic forming and diffusion bonding
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GB0203955D0 (en) * 2002-02-20 2002-04-03 Rolls Royce Plc A method of manufacturing an article by diffusion bonding and super[lastic forming
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JPH01289531A (ja) * 1988-05-17 1989-11-21 Nippon Steel Corp 超塑性鍛造法
JPH0280149A (ja) * 1988-09-16 1990-03-20 Agency Of Ind Science & Technol タービンブレードの鍛造プリフォームの成形方法及び成形金型
US5636440A (en) 1994-09-07 1997-06-10 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Process for manufacturing a hollow blade for a turbo-machine
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101773972A (zh) * 2010-02-25 2010-07-14 无锡透平叶片有限公司 一种高强铝合金坯料的制坯工艺
CN102836946A (zh) * 2012-09-11 2012-12-26 四川豪特石油设备有限公司 600mw机组汽轮机末级动叶片辊锻成形工艺
CN102836946B (zh) * 2012-09-11 2014-11-05 四川豪特石油设备有限公司 600mw机组汽轮机末级动叶片辊锻成形工艺
EP2924244A4 (de) * 2012-12-19 2016-03-09 Mitsubishi Hitachi Power Sys Verfahren zur herstellung eines turbinenrotorblatts
US9919392B2 (en) 2012-12-19 2018-03-20 Mitsubishi Hitachi Power Systems, Ltd. Method for manufacturing turbine rotor blade
WO2021116086A1 (fr) * 2019-12-09 2021-06-17 Safran Aero Boosters Sa Procédé de fabrication d'une aube de compresseur
BE1027837B1 (fr) * 2019-12-09 2021-07-05 Safran Aero Boosters S.A. Procédé de fabrication d'une aube de compresseur

Also Published As

Publication number Publication date
RU2383408C2 (ru) 2010-03-10
FR2874339A1 (fr) 2006-02-24
CN1721129A (zh) 2006-01-18
US20070240307A1 (en) 2007-10-18
FR2874339B1 (fr) 2008-12-05
US8683689B2 (en) 2014-04-01
RU2005126598A (ru) 2007-02-27

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