A two-stage brush seal filament welding method, system, apparatus, and storage medium
By establishing a three-dimensional solid model and performing finite element analysis, the problem of optimizing welding parameters in the traditional brush seal welding method was solved, and accurate prediction of temperature and stress fields was achieved, thereby improving welding quality and process reliability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- AVIC BEIJING AERONAUTICAL MFG TECH RES INST
- Filing Date
- 2026-05-28
- Publication Date
- 2026-07-24
AI Technical Summary
Traditional brush-type sealing wire welding methods rely on manual experience, have long test cycles, serious material waste, and make it difficult to accurately obtain the temperature and stress field distribution during the welding process. Optimizing welding parameters is also difficult, and the performance of the welded joint is hard to achieve the ideal state.
By establishing a three-dimensional solid model of the brush seal test piece, performing finite element mesh generation and multi-field coupling calculation, accurate prediction of welding temperature field, stress field and deformation can be achieved, and welding process parameters can be optimized.
It significantly improves welding quality and process reliability, reduces material waste, and enhances the accuracy of welding temperature and stress field distribution. It is suitable for welding quality assessment and process improvement of brush seals with complex structures.
Smart Images
Figure CN122454097A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of welding technology for brush-type seal bristles, and more particularly to a method, system, equipment, and storage medium for welding two-stage brush-type seal bristles. Background Technology
[0002] In aero-engines, the welding of bladed disks and journals often employs brush seal welding technology. The quality of the brush seal welding directly affects its sealing performance and service life. Traditional brush welding methods rely on manual testing of various welding parameters, which is time-consuming, costly, and makes it difficult to accurately obtain the residual stress and temperature field distribution after welding, severely impacting the reliability and consistency of the weld quality.
[0003] The shortcomings of existing technologies are: traditional methods rely on worker experience, have long test cycles, and result in serious material waste; it is difficult to fully obtain the temperature and stress field distribution during the welding process through experimental means; it is difficult to optimize welding parameters, and the performance of welded joints is difficult to achieve the ideal state; and it is impossible to systematically predict and optimize the process before welding. Summary of the Invention
[0004] This invention provides a two-stage brush-type sealing brush wire welding method, system, equipment, and storage medium to solve the problems mentioned in the background art.
[0005] In a first aspect, the present invention provides a method for welding two-stage brush-type sealing brush wires, comprising: Based on the actual structural data of the brush seal test specimen, a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal was established. The three-dimensional solid model is divided into finite element meshes to form several mesh elements of the brush bundle and front and rear baffle solid models, so as to carry out finite element analysis after welding. The process parameters and boundary conditions for welding the brush bristles and front and rear baffles were set, and temperature field analysis, indirect thermo-mechanical coupling stress field calculation and mechanical property analysis were performed respectively.
[0006] Further, the step of performing finite element mesh generation on the three-dimensional solid model includes: The three-dimensional solid model is geometrically cleaned up by deleting free nodes, then overlapping nodes and overlapping units are merged and repeatedly confirmed. The selected hexahedron of the three-dimensional solid model is meshed, with the area near the weld and the area close to the weld being divided into a dense mesh, and other areas being divided into a sparse mesh. The mesh is then inspected for quality.
[0007] Furthermore, the process parameters include power, focusing current, welding current, rotation speed, amplitude, and scanning frequency.
[0008] Furthermore, the power is 1200W; the focusing current is 1955~1990mA; the welding current is 9~15mA; the rotation speed is 6~7mm / s; the amplitude is X=2, Y=4; and the scanning frequency is 500Hz.
[0009] Furthermore, the temperature field analysis includes generating the heat input range and temperature distribution region for welding the brush filaments to the front and rear baffles.
[0010] Furthermore, the stress field calculation includes steady-state solution through finite element software analysis, setting the brush temperature, opening the energy equation and structural analysis to obtain the stress distribution diagram.
[0011] Furthermore, the mechanical property analysis includes applying temperature and boundary conditions to the tip of the brush filament and performing mechanical property analysis in welding numerical simulation software.
[0012] Secondly, the present invention provides a two-stage brush-type sealing wire welding system, comprising: The model building module is used to build a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal based on the actual structural data of the brush seal test piece. The mesh generation module is used to perform finite element mesh generation on the three-dimensional solid model to form several mesh elements of the brush bundle and front and rear baffle solid models, so as to perform finite element analysis after welding. The welding analysis module is used to set various process parameters and boundary conditions for welding the brush filaments and front and rear baffles, and to perform temperature field analysis, indirect thermo-coupling stress field calculation, and mechanical property analysis.
[0013] Thirdly, the present invention provides a terminal device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the two-stage brush-type sealing wire welding method as described above.
[0014] Fourthly, the present invention provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the two-stage brush-type sealing wire welding method as described above.
[0015] The above-described technical solution of the present invention has the following advantages: The first aspect of this invention provides a method for welding brush wires in a two-stage brush seal. Based on the actual structural data of the brush seal test piece, a three-dimensional solid model of the brush seal's leakage and heat transfer characteristics is established. This three-dimensional solid model is then meshed using finite element methods to form several mesh elements for the brush wire bundle and the front and rear baffle solid models, facilitating finite element analysis after welding. Various process parameters and boundary conditions for welding the brush wires and the front and rear baffles are set, and temperature field analysis, indirect thermo-mechanical coupling stress field calculation, and mechanical property analysis are performed. By establishing a three-dimensional solid model, performing finite element analysis, and conducting multi-field coupling calculations, accurate prediction of the welding temperature field, stress field, and deformation is achieved, significantly improving welding quality and process reliability.
[0016] It is understood that the beneficial effects of the second, third and fourth aspects mentioned above can be found in the relevant descriptions in the first aspect above, and will not be repeated here. Attached Figure Description
[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0018] Figure 1 This is a flowchart of a two-stage brush-type sealing wire welding method provided in an embodiment of the present invention; Figure 2 A schematic diagram of a three-dimensional solid model provided in an embodiment of the present invention; Figure 3 A partitioning diagram of a three-dimensional solid model provided in an embodiment of the present invention; Figure 4 The temperature field simulation results are shown in the figure provided for the embodiments of the present invention; Figure 5 The stress distribution diagram is a simulation result diagram provided in the embodiment of the present invention; Figure 6 The diagram shows the mechanical property analysis results provided in the embodiments of the present invention. Detailed Implementation
[0019] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of the invention. However, those skilled in the art will understand that the invention can be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the invention with unnecessary detail.
[0020] It should be understood that, when used in this specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.
[0021] Furthermore, in the description of this invention and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0022] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of the invention include a particular feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized. "A plurality" means "two or more."
[0023] This invention provides a two-stage brush-type sealing wire welding method based on numerical simulation. By establishing a three-dimensional solid model, finite element analysis and multi-field coupling calculation, it can accurately predict the welding temperature field, stress field and deformation, which significantly improves welding quality and process reliability.
[0024] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.
[0025] This invention provides a method for welding two-stage brush-type sealing brush filaments, such as... Figure 1 As shown, the process includes: establishing a three-dimensional solid model of the brush seal leakage and heat transfer characteristics based on the actual structural data of the brush seal test piece; dividing the three-dimensional solid model into finite element meshes to form several mesh elements of the brush filament bundle and the front and rear baffle solid models for finite element analysis after welding; setting various process parameters and boundary conditions for welding the brush filament and the front and rear baffles, and performing temperature field analysis, indirect thermo-coupling stress field calculation, and mechanical property analysis respectively.
[0026] In some embodiments, the step of performing finite element mesh generation on the three-dimensional solid model includes: performing geometric cleanup on the three-dimensional solid model, deleting free nodes in the model, then merging coincident nodes and coincident elements, and performing repeated confirmation; performing mesh generation on the selected hexahedron of the three-dimensional solid model, dividing the area near the weld seam and the near-weld area into a dense mesh, and dividing other areas into a sparse mesh, and performing quality checks on the divided mesh.
[0027] In some embodiments, the process parameters include power, focusing current, welding current, rotation speed, amplitude, and scanning frequency.
[0028] In some embodiments, the power is 1200W; the focusing current is 1955~1990mA; the welding current is 9~15mA; the rotation speed is 6~7mm / s; the amplitude is X=2, Y=4; and the scanning frequency is 500Hz.
[0029] In some embodiments, the temperature field analysis includes generating the heat input range and temperature distribution region for welding the brush filaments to the front and rear baffles.
[0030] In some embodiments, the stress field calculation includes steady-state solution through finite element software analysis, setting the brush temperature, opening the energy equation and structural analysis to obtain the stress distribution diagram.
[0031] In some embodiments, the mechanical property analysis includes applying temperature and boundary conditions to the tip of the brush filament and performing mechanical property analysis in welding numerical simulation software.
[0032] This invention addresses the difficulty in verifying the residual stress and temperature field distribution after welding brush filaments for brush seals in aero engines. It provides a two-stage brush filament welding method, the specific implementation of which is as follows: Based on the actual structural data of the brush seal test specimen, a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal was established, such as... Figure 2 As shown; the 3D solid model is meshed using the finite element method to form several mesh elements for the brush filament bundle and the front and rear baffle solid models, in order to perform finite element analysis after welding, as shown. Figure 3 As shown in Table 1, various process parameters for the brush and front and rear baffles were set in the welding numerical simulation software; temperature field analysis, indirect thermo-coupling stress field calculation, and mechanical property analysis were performed.
[0033] Table 1 Process Parameter Settings The steps for finite element mesh generation of a 3D solid model include: geometric cleanup of the 3D solid model, first deleting free nodes in the model, then merging coincident nodes and coincident elements, and repeating the confirmation; meshing of a selected hexahedron of the 3D solid model, dividing the area near the weld and the near-weld area into a dense mesh, and dividing other areas into a sparse mesh; and quality checking of the mesh.
[0034] To address the challenges of traditional brush welding methods that rely on manual testing of various welding parameters, resulting in time-consuming and costly processes, the advancements of this invention are as follows: Numerical simulation replaces extensive physical testing, avoiding the waste of numerous test pieces; it improves the accuracy of welding simulation, yielding higher-quality welding temperature and stress field distributions; and it is suitable for welding quality assessment and process improvement of complex brush seal structures.
[0035] After mesh generation and welding process parameter setting using the method provided by this invention, the heat input range and temperature distribution region for welding the brush filaments to the front and rear baffles are generated, achieving the temperature field simulation results as shown in the figure. Figure 4 As shown, the highest melting point is 586℃. The temperature is conducted to the surrounding area through the welding process. The temperature gradient is larger at the front end of the welding position and smaller at the rear end. The temperature gradient decreases as you get closer to the tail end.
[0036] Based on the temperature field calculation, the stress field of indirect thermo-coupling is calculated. Steady-state solution is obtained through finite element analysis software. The brush filament temperature is set, and the energy equation and structural analysis are enabled to obtain the stress distribution diagram simulation results. Figure 5 As shown, the maximum stress is 11871 Pa and the minimum stress is 0.12468 Pa.
[0037] Temperature and boundary conditions were applied to the tip of the brush bristles, and mechanical property analysis was performed in welding numerical simulation software. The deformation results are as follows: Figure 6 As shown in the analysis results, the maximum deformation at the contact point between the front and rear baffles and the brush bristles is at the contact point between the brush bristles and the inner diameter of the brush ring. The deformation of the front baffle is 0.019 mm, the deformation of the rear baffle is 0.021 mm, and the deformation of the free end of the brush bristles is the largest, at 0.057256 mm.
[0038] The dual-stage brush-type sealing brush welding method provided by this invention achieves accurate prediction of welding temperature field, stress field and deformation by establishing a three-dimensional solid model, finite element analysis and multi-field coupling calculation, which significantly improves welding quality and process reliability.
[0039] Corresponding to the two-stage brush-type sealing wire welding method described in the above embodiments, this invention also provides a two-stage brush-type sealing wire welding system, comprising: The model building module is used to build a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal based on the actual structural data of the brush seal test piece. The mesh generation module is used to perform finite element mesh generation on the three-dimensional solid model to form several mesh elements of the brush bundle and front and rear baffle solid models, so as to perform finite element analysis after welding. The welding analysis module is used to set various process parameters and boundary conditions for welding the brush filaments and front and rear baffles, and to perform temperature field analysis, indirect thermo-coupling stress field calculation, and mechanical property analysis.
[0040] It should be noted that the information interaction and execution process between the above modules / units are based on the same concept as the method embodiments of the present invention. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.
[0041] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this invention. The specific working process of the units and modules in the above device can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0042] This invention also provides a terminal device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the two-stage brush-type sealing wire welding method provided in the first aspect.
[0043] In applications, terminal devices may include, but are not limited to, processors and memory. These are merely examples of terminal devices and do not constitute a limitation on them. They may include more or fewer components, combinations of certain components, or different components, such as input / output devices and network access devices. Input / output devices may include cameras, audio capture / playback devices, displays, etc. Network access devices may include network modules for wireless network communication with external devices.
[0044] In applications, the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor.
[0045] In applications, the memory may be an internal storage unit of the terminal device in some embodiments, such as the hard drive or RAM of the terminal device. In other embodiments, the memory may be an external storage device of the terminal device, such as a plug-in hard drive, smart media card (SMC), flash card, etc., provided on the terminal device. The memory may also include both internal and external storage units of the terminal device. The memory is used to store the operating system, applications, boot loader, data, and other programs, such as the program code of computer programs. The memory can also be used to temporarily store data that has been output or will be output.
[0046] This invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, can implement the steps in the above-described method embodiments.
[0047] The present invention implements all or part of the processes in the methods of the above embodiments by instructing related hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable file, or some intermediate form. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to a terminal device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, such as a USB flash drive, a portable hard drive, a magnetic disk, or an optical disk.
[0048] Those skilled in the art will recognize that the device and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.
[0049] In the embodiments provided by this invention, it should be understood that the disclosed devices and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. Furthermore, the couplings or direct couplings or communication connections shown or discussed may be through some interfaces, or indirect couplings or communication connections between devices, and may be electrical, mechanical, or other forms.
[0050] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.
Claims
1. A method for welding two-stage brush-type sealing brush filaments, characterized in that, include: Based on the actual structural data of the brush seal test specimen, a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal was established. The three-dimensional solid model is divided into finite element meshes to form several mesh elements of the brush bundle and front and rear baffle solid models, so as to carry out finite element analysis after welding. The process parameters and boundary conditions for welding the brush bristles and front and rear baffles were set, and temperature field analysis, indirect thermo-mechanical coupling stress field calculation and mechanical property analysis were performed respectively.
2. The method for welding two-stage brush-type sealing brush wires as described in claim 1, characterized in that, The step of performing finite element mesh generation on the three-dimensional solid model includes: The three-dimensional solid model is geometrically cleaned up by deleting free nodes, then overlapping nodes and overlapping units are merged and repeatedly confirmed. The selected hexahedron of the three-dimensional solid model is meshed, with the area near the weld and the area close to the weld being divided into a dense mesh, and other areas being divided into a sparse mesh. The mesh is then inspected for quality.
3. The method for welding two-stage brush-type sealing brush wires as described in claim 1, characterized in that, The process parameters include power, focusing current, welding current, rotation speed, amplitude, and scanning frequency.
4. The method for welding two-stage brush-type sealing brush wires as described in claim 3, characterized in that, The power is 1200W; the focusing current is 1955~1990mA; the welding current is 9~15mA; the rotation speed is 6~7mm / s; the amplitude is X=2, Y=4; and the scanning frequency is 500Hz.
5. The method for welding two-stage brush-type sealing brush wires as described in claim 1, characterized in that, The temperature field analysis includes generating the heat input range and temperature distribution region for welding the brush filaments to the front and rear baffles.
6. The method for welding two-stage brush-type sealing brush wires as described in claim 1, characterized in that, The stress field calculation includes steady-state solution through finite element software analysis, setting the brush temperature, opening the energy equation and structural analysis to obtain the stress distribution diagram.
7. The method for welding two-stage brush-type sealing brush wires as described in claim 1, characterized in that, The mechanical property analysis includes applying temperature and boundary conditions to the tip of the brush filament and performing mechanical property analysis in welding numerical simulation software.
8. A two-stage brush-type sealing wire welding system, characterized in that, include: The model building module is used to build a three-dimensional solid model of the leakage and heat transfer characteristics of the brush seal based on the actual structural data of the brush seal test piece. The mesh generation module is used to perform finite element mesh generation on the three-dimensional solid model to form several mesh elements of the brush bundle and front and rear baffle solid models, so as to perform finite element analysis after welding. The welding analysis module is used to set various process parameters and boundary conditions for welding the brush filaments and front and rear baffles, and to perform temperature field analysis, indirect thermo-coupling stress field calculation, and mechanical property analysis.
9. A terminal device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the two-stage brush-type sealing wire welding method as described in any one of claims 1 to 7.
10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the two-stage brush-type sealing wire welding method as described in any one of claims 1 to 7.