盘上周向开槽的燕尾榫联接的应力和微动磨损疲劳分析——用模型代替实物作研究

用结构模型代替实物,可以节约研究经费和时间,且可以得到满意结果。采用此法研究盘上周向开槽的燕尾榫联接的应力分布和微动磨损疲劳。对盘上榫槽和叶片榫头作了计算和实验分析,得到了较满意的结果。所用方法也可以推广应用到其他动力机械中的榫联接的研究。     

Mixed high low fretting fatigue of Ti6Al4V: Tests and modelling

In this paper fretting fatigue tests under a combined HCF/LCF loading regime are reported. This loading cycle is representative of operating conditions at the interface of the dovetail fixing between fan and blade in an aeroengine, although a classical geometry was considered, viz. the contact of cylinders against a ground flat tensile specimen. Both, specimen and pads were made of fan blade and disc alloy Ti6Al4V. The main objective of these experiments was to investigate the influence of such complex contact loads on the fretting damage and most importantly on fretting fatigue. A methodology to estimate total life is proposed and assessed against the experimental data. The results show that the main effect on fretting fatigue life is associated with the level of tangential force and that the predictive method was able to capture the effect of the experimental parameters on life, together with the influence of the residual stress field due to shot peening.     

Modal characteristics and fatigue strength of compressor blades

High-cycle fatigue (HCF) has been identified as one of the primary causes of gas turbine engine failure. The modal characteristics and endurance strength of a 5 MW gas turbine engine blade developed by Doosan Heavy Industries & Construction Co., Ltd. in HCF fracture were verified through analysis and tests to determine the reliability of the compressor blade. A compressor blade design procedure that considers HCF life was performed in the following order: airfoil and blade profile design, modal analysis, stress distribution test, stress endurance limit test, and fatigue life verification. This study analyzed the Campbell diagram and estimated resonance risk on the basis of the natural frequency analysis and modal test of the compressor blade to guarantee safe and operational reliability. In addition, the maximum stress point of the compressor blade was determined through stress distribution analysis and test. The bonding point of the strain gage was determined by using fatigue test. Stress endurance limit test was performed based on the results of these tests. This research compared and verified the modal characteristics and endurance strengths of the compressor blades to prevent HCF fracture, which is among the major causes of gas turbine engine damage. A fatigue life design procedure of compressor blades was established. The 5 MW class gas turbine compressor blade is well designed in terms of resonance stability and fatigue endurance limit.     

起动机动力涡轮叶片断裂故障研究与改进

系统归纳了动力涡轮叶片断裂故障的基本特征,分析了叶片断裂的根本原因在于叶片的一阶弯曲共振。在弯曲共振无法避免的情况下,从提高动力涡轮叶片的疲劳抗力入手,采用细晶＋方向性凝固＋热等静压的复合成型工艺,成功地解决了这一故障。     

燃气涡轮转子盘-片系统三维非线性循环应力-应变分析

燃气涡轮转子盘—片系统的几何形状和结构形式比较复杂，在高温、高转速的恶劣条件下工作，准确的应力分析是进行强度计算和疲劳寿命预测的重要前提。使用ANSYS有限元结构分析软件，建立了燃气涡轮盘—片接触系统三维循环对称有限元模型，考虑了叶片材料的各向异性、涡轮盘与叶片榫头之间的接触非线性、材料的弹塑性变形和温度不均匀引起的热应力等情况，数值模拟涡轮盘—叶片组件的受力状态及边界条件，进行三维非线性循环应力—应变分析。     

复合应力对接触疲劳的影响

作者采用统计学的实验和数据处理方法,研究复合应力对接触疲劳的影响。实验结果表明,附加拉伸弯曲应力显著地缩短接触疲劳寿命。而压缩弯曲应力的影响,则取决于它的数值大小。较小的附加压缩应力能够增加疲劳寿命,而大的压缩应力将促进疲劳发生。存在一个临界压缩弯曲应力值,此时疲劳寿命为最大值。根据实验结果,作者就通常计算接触疲劳强度所采用的几种决定应力的适用性提出分析和评价。以最大的表面剪切应力作为决定应力更适合于接触疲劳问题,复合应力作用下的接触疲劳裂纹可能发源于金属表面。     

压弯组合应力下高强钢焊接板表面裂纹疲劳寿命计算

潜艇上浮下潜运动使得其耐压壳承受交变的外压载荷。潜艇耐压壳的疲劳热点为锥一柱过渡结构连接焊缝焊趾处，该处所受的应力特征为压弯组合应力。压弯组合应力下表面裂纹应力强度因子及其疲劳寿命的计算尚无报道。弄清楚压弯组合应力作用下带表面裂纹焊接板试件的疲劳特性对潜艇等结构的疲劳研究是必要的。文中提出用成一定角度的对接焊板试件和轴向加载获得压弯组合应力来模拟潜艇耐压壳锥一柱焊接结合区的应力特征的实验方法。用980高强钢作试件，研究焊趾处预制表面裂缝，并在压弯组合应力为特征的疲劳载荷作用下表面裂纹的疲劳行为。给出高强钢焊趾表面裂纹在压弯组合应力下应力强度因子及其疲劳寿命计算式。该结果可供海洋平台、压力容器及管道的某些受力特征为压弯组合应力的重要结构的疲劳设计时参考。     

Semi-analytical solution of magneto-thermo-elastic stresses for functionally graded variable thickness rotating disks

In this paper, a semi-analytical solution for magneto-thermo-elastic problem in functionally graded (FG) hollow rotating disks with variable thickness placed in uniform magnetic and thermal fields is presented. Stresses and perturbation of magnetic field vector in FG rotating disks are determined using infinitesimal theory of magneto-thermo-elasticity under plane stress conditions. The material properties except Poisson’s ratio are modeled as power-law distribution of volume fraction. The profile of disk thickness is assumed to be a parabolic function of radius. The non-dimensional distribution of temperature, displacement, stresses and perturbation of magnetic field vector throughout radius are shown. Effects of material grading index, geometry of the disk and magnetic field on the stress and displacement fields are investigated. The results of stresses and radial displacements for two different boundary conditions with and without the effect of magnetic field are compared for a FG rotating disk with concave thickness profile. It has been found that imposing a magnetic field significantly decreases tensile circumferential stresses. Therefore the fatigue life of the disk will be significantly improved by applying the magnetic field. Results of this investigation could be applied for optimum design of FG hollow rotating disks with variable thickness.     

Dynamic test and fatigue life evaluation of compressor blades

High-cycle fatigue (HCF) has been identified as one of the primary causes of gas turbine engine failure. To verify the reliability of the high cycle fatigue fracture of the 5 MW gas turbine engine blade being developed by Doosan Heavy Industries & Construction Co., Ltd., dynamic tests were conducted using real size compressor rigs according to previous studies. The dynamic safety margin of the 5MW gas turbine engine blade was calculated on the basis of the ratio between the dynamic stress and endurance limit stress respectively determined through the compressor rig and fatigue tests. The HCF characteristics and the fatigue life stability of the DGT-5 compressor blades were verified through these processes. A fatigue life design procedure for the gas turbine compressor blade was established on the basis of the design, analysis, and test processes implemented in a previous study. In sum, the 5 MW class gas turbine compressor blades were found to be well designed in terms of resonance stability and fatigue life.     

Elevated Temperature Evaluation of Fretting and Metal Transfer between Coated Titanium Components

During fretting, small amplitude displacements and high normal surface loads combined with abrasive oxide particles cause surface damage that acts as initiation sites for fatigue cracks. Since these conditions are prevalent within the titanium dovetail joints of jet engines a wear mode analysis was performed on extended service jet engine disks and compressor blades. The results of the wear mode analysis indicated that titanium from the uncoated disk was transferred to the softer copper-nickel-indium coated dovetail surface of the blades. This transfer created titanium on titanium contact and eventually fretting wear. In order to simulate these conditions, a moderate displacement (125 μm), low cycle phase followed by a small displacement (25 μm), high cycle fretting phase utilizing a cylinder on flat configuration was developed. The analysis and test procedure developed during this study will ultimately aid in the selection and evaluation of a new coating capable of preventing fretting.     

重型燃气轮机叶片离心载荷下应力特性的研究

针对重型燃气轮机叶片疲劳寿命研究的需要,通过设计和搭建的全尺寸叶片疲劳试验装置,模拟离心载荷工况下的低周疲劳试验,开展离心载荷下叶片应力分布和疲劳寿命预测的研究。该全尺寸叶片疲劳试验装置能够模拟低周疲劳中的等效离心载荷工况,为叶片试验提供必要的条件和手段。同时,对叶片进行网格划分和有限元仿真计算后,得到叶片Von mises应力分布结果,发现叶身应力最大处位于中部偏下边缘薄壁侧。然后将有限元仿真及应力试验相结合,提出叶片疲劳试验的离心载荷等效方法。在此基础上完成叶片的动应力试验,获得应力时间历程数据,并且给出离心载荷应力谱。结果表明,叶身中部边缘的应力水平最高,动应力谱幅值与频数概率的分布服从6阶麦克劳林拟合函数,用等效离心载荷疲劳寿命进行叶片寿命预测的结果是偏安全的,该结论可作为优化设计和试验研究的参考依据。     

A method of determining test load for full-scale wind turbine blade fatigue tests

Full-scale fatigue test is an effective method for validating the fatigue performance of wind turbine blade. Its primary problem is how to design the test load. The conventional approach to determine test load requires a complicated and time-consuming process. Thus, a simplified method for directly converting load spectrum of blade into test load is proposed in this paper. Firstly, beam theory is used to obtain the relationship between stress, strain and bending moment of blade cross section. Based on the assumption of local stress concentration and linear relationship between stress and strain, M-N curves (applied moment vs. allowable number of cycles to failure) is defined. Secondly, based on Miner's linear cumulative damage theory and constant life diagram, the equivalent fatigue cumulative damage of load spectrum which is equal to the damage of full-scale fatigue test is obtained. Then, in the case of the selected test load ratio and cycles, the mean and amplitude of test load can be solved. Finally, the validity of the proposed method is verified by an illustrative example. The result indicates that the error of the calculated results between this method and the traditional method is close to 5 %, and it can be used for fatigue test and improve the efficiency of test load design.     

Vibration localization of a mistuned rotating multi-packet blade system undergoing external cyclic harmonic force

A multi-packet blade system consists of several blades which are attached to a disk and connected through shrouds. The blades of a multi-packet blade system are usually assumed to be identical. However, there always exists small, random mistuning among the blades due to manufacturing tolerance, in-operation wear and environmental changes. Such mistuning may cause significant increase in the forced vibration responses of some blades in the multi-packet blade system. Critical fatigue problems often occur in mistuned systems since the forced vibration response of a mistuned system is often significantly larger than that of a tuned system. Therefore, it is very important to predict the maximum blade response. In this study, blades are idealized as cantilever beams and the flexibilities of the disk and shrouds are idealized as discrete springs. Equations of motion are derived using the hybrid deformation variable method. To realize vibration localization with random mistuning, transient analysis is carried out for a multi-packet blade system excited by multiple nozzle jet forces.     

叶盘结构频率转向特征及失谐敏感性实验研究

搭建了用于失谐叶盘结构固有特性及失谐敏感性研究的实验平台,对谐调叶盘结构的频率转向现象进行了实验研究,验证了以往理论分析和有限元仿真中发现的频率转向特征和模态振型转换现象;通过在叶尖粘贴不同的质量块,模拟了三种典型的叶片失谐形式,实验研究了失谐叶盘结构的模态局部化问题;针对同一叶片失谐形式下不同的模态密度区域,实验研究了模态密度对失谐敏感性的影响规律。实验结果与有限元实验仿真结果吻合较好。     

回转圆盘薄片刀具横向振动控制研究

针对高速回转圆盘薄片刀具实际工作时存在的横向振动问题，应用有限元方法和拉格朗日方程建立了高速回转圆盘薄片刀具的动力学方程。在此基础上，根据流体动压润滑理论，研究了一种高速圆盘薄片刀具横向振动控制器，利用高速圆盘薄片刀具的回转运动和横向振动来形成流体压力膜，抑制圆盘薄片刀具的横向振动。理论分析表明，这种利用流体动压润滑原理工作的控制器可以有效地减少高速圆盘薄片刀具横向振动的幅值。     

流固耦合下轴流压气机叶片振动特性数值研究

气流扰动触发的叶片振动是导致叶片疲劳失效的主要原因,针对此问题,首先,建立叶片流固耦合时域计算模型,研究叶片振动特性,并进行叶片失效分析;其次,建立压气机叶片振动分析模型,结合叶片振动试验来验证模型的有效性;然后,考虑气体与叶片的耦合作用,通过数值仿真模拟得到典型工况下的叶片表面气动载荷,并将其引入旋转叶片有限元振动分析模型进行叶片振动响应计算;最后,引入坎贝尔图确定叶片危险工况,得到危险工况下的叶片动应力分布,并进行叶片疲劳失效分析。结果表明:临界工况下叶片振动应力分布与发生共振的模态振型密切相关;临界转速下叶片发生的1阶共振是造成叶片失效的主因。     

Multiscale computation of fretting wear at the blade/disk interface

Dovetail joints between fan blades and the disk of turbine engines are subjected to fretting. The objective of this research is to realize wear prediction by computational methods. The goal is obviously the estimation of wear kinetics, but also to obtain worn surfaces, and permit the manufacturer to realize complementary design analyses with worn surfaces. A wear law developed for titanium alloy and based on the friction dissipated energy is used. A computational method based on a three scale analysis is presented. The originality consists of coupling a semi-analytical (SA) contact solver with the FE method for the structural behavior, allowing a fine discretization of the contact zone. Contact computations are fast enough to realize cyclic wear computations. Results for the blade/disk system are exhibited.     

用有限元法进行结构强度计算时极限应力的确定

有限元法在结构强度的分析与计算中的应用越来越广泛 ,但是在分析中相应极限应力的确定尚存在一定的误区。本文应用“当量设计”的概念 ,针对这一误区进行了深入研究 ,揭示了用有限元法进行结构强度计算时 ,合理确定极限应力的方法与应注意的问题。通过对实验结果的分析 ,给出了对航空齿轮有限元分析时相应的齿根弯曲疲劳极限。     

多工况下离心压缩机叶片承载的流固耦合效应分析

针对国内某大型离心压缩机叶轮叶片利用流固耦合技术,通过求解流体和固体的耦合方程,对冬季和设计工况下的叶轮叶片的应力应变分别进行了计算分析。理论分析表明,叶轮叶片的应力主要由离心力引起的拉应力和气动载荷引起的叶片弯应力构成。数值计算表明：对所研究的离心叶轮而言,离心力产生的拉应力是构成叶片应力的主要因素,而气动载荷引起的叶片应力相对较小;但单独进行力学分析其危险工作面的位置会发生变化,计算结果显示应力应变异常区域与实际叶片发生断裂的部位相一致。本文研究结果为实际运行发生事故的原因分析提供一定的依据。     

0．5T气动葫芦马达的设计计算

以0．5T气动葫芦为研究对象，对其马达进行了结构设计，并从运动学和动力学角度对马达叶片进行了计算和校核，确定了叶片所受的各种外力和各种惯性力，找出了叶片接触和弯曲疲劳的最危险截面，并进行了弯曲和疲劳强度校核计算，以最终确定了叶片的几何尺寸及形状。该计算过程和结果为0．5t气动葫芦的马达设计提供了理论依据。