A method for additive manufacturing design of compressor anti-surge spoiler casing for spatially profiled thin-walled structure

Abstract

The application provides a kind of for space heterotypic thin-walled structure's compressor anti-surge spoiler casing additive manufacturing design method, its method content mainly includes: the integration design of spoiler and connecting flange, the segmentation of spoiler casing, the additive manufacturing placement design of spoiler casing, the weight reduction of spoiler casing, the support-free design of spoiler casing functional surface.The application fully considers the characteristics of additive manufacturing process in design, realizes the integration design and processing of the compressor anti-surge spoiler casing of space heterotypic thin-walled structure.The method of the application is ingenious, and the processing efficiency of additive manufacturing is high, finally forms a kind of for space heterotypic thin-walled structure's compressor anti-surge spoiler casing additive manufacturing design method, which can also provide design reference for similar part design and processing in additive manufacturing field and similar products of gas turbine.

Description

Technical Field

[0001] This invention belongs to the field of additive manufacturing, specifically relating to an additive manufacturing design method for compressor anti-surge baffle casing for spatial irregular thin-walled structures. Background Technology

[0002] The anti-surge spoiler casing for gas turbine compressors is used to expand the compressor's stable operating range and optimize the unit's margin of efficiency under a wide range of varying operating conditions. Its basic principle is as follows: the anti-surge spoiler casing causes the low-energy fluid mass originally located at the tip of the moving blades to enter the spoiler channels due to inertia as the blades rotate. Under the action of axial pressure difference, it is guided by the spoiler and then re-enters the main flow path. This reduces the low-speed region at the tip of the moving blades and changes the intake direction, reducing the intake angle of attack. This dual effect improves the compressor's flow capacity, increases its stable operating range, and minimizes efficiency reduction.

[0003] The anti-surge spoiler casing designed based on the above principles contains a large number of spoilers (typically 140 to 160), and the spoilers are designed as spatially irregular thin-walled structures with a wall thickness of 3 to 4 mm. The maximum outer diameter of the spoilers along the radial direction (referring to the flow path of the gas turbine compressor) is 900 mm to 1000 mm, the radial height of the spoilers is about 10 mm, and the angle along the radial height can vary from 60° to 70°, resulting in drastic torsion changes. The original design of the spoiler casing was achieved through traditional machining and assembly processes, with both ends connected and fixed to the end flanges by pins or ferrules. In the traditional production process, it requires multiple processing steps such as forging, machining, positioning assembly, welding, and heat treatment, and the processing cycle is also long, generally requiring 4 to 6 months. In terms of reliability, there is a risk of poor reliability in the connection between the spoilers and the end flanges, and breakage failures have occurred during unit testing. Summary of the Invention

[0004] The purpose of this invention is to provide an additive manufacturing design method for compressor anti-surge turbulence vane casing for spatial irregular thin-walled structures, so as to realize the integrated design of spatial structures and efficient and reliable additive manufacturing processing.

[0005] An additive manufacturing design method for compressor anti-surge turbulence vane casing for spatial irregular thin-walled structures, characterized by comprising the following steps:

[0006] Step 1: Combining the characteristics of selective laser melting metal additive manufacturing process and the structural features of the compressor anti-surge spoiler casing with a spatial irregular thin-walled structure, selective laser melting metal 3D printing technology and process are used to design and manufacture the compressor.

[0007] Step 2: The compressor anti-surge turbulence vane casing is designed and controlled through structural design in additive manufacturing, resulting in a highly integrated, lightweight, and unsupported functional surfaces.

[0008] Step 3: The anti-surge baffle in the compressor housing is designed as an integrated structure with its axial end flange. The baffle and the end flange are connected and transitioned through rounded corners, completely avoiding the assembly and connection of multiple parts.

[0009] Step 4: Divide the compressor anti-surge spoiler housing from Step 3 along the installation angle of the spoilers on the inlet and outlet sides to enable segmented simultaneous printing of selective laser melting metal 3D printing on a limited forming platform;

[0010] Step 5: Design the internal structure of the flange connecting the two axial ends of the compressor anti-surge baffle in Step 4 as a regular discontinuous rectangular cavity structure to achieve the purpose of weight reduction and material reduction.

[0011] Step 6: Perform additive manufacturing placement optimization design on the segmented spoiler housing formed in Step 4 and Step 5. Analyze and design that the forming angles α to β of all spoiler functional surfaces should be within the range of additive manufacturing self-forming without support, and that the powder consumption hmin and hmax of one-time forming for rapid prototyping should be minimized.

[0012] Step 7: The angle between the thin-walled spoiler structure with the spatial irregular surface and the reference plane of the selective laser melting metal 3D printing meets the unsupported design requirements in the manufacturing process. If it is necessary to adjust the original design twist direction of the spoiler during placement, the anti-surge performance needs to be recalculated after adjustment. If the design requirements are not met, the twist direction of the spoiler needs to be redesigned in combination with the angular direction required by additive manufacturing, and the work of steps 1 to 6 is repeated.

[0013] Furthermore, in step 1, the selective laser melting metal 3D printing is achieved by designing and manufacturing the spoiler housing in a segmented manner. The spoiler housing ring is divided into sections based on the forming dimensions of the additive manufacturing equipment and the requirement of unsupported design for all functional surfaces of the spoiler.

[0014] Furthermore, the support connection structure of the anti-surge bleed plate housing and the selective laser melting metal 3D printing substrate is designed as a triangular groove-shaped solid structure to achieve unsupported one-time molding of all functional surfaces and stable additive manufacturing molding.

[0015] The beneficial effects of this invention are as follows:

[0016] (1) The present invention realizes additive manufacturing design and manufacturing of similar irregular thin-walled structures, which has the advantages of high integration, zero assembly, zero welding and stable structure;

[0017] (2) The present invention achieves the goal of high efficiency in one-time molding and saving printing materials.

[0018] (3) The spoiler casing structure of the present invention has high reliability. Attached Figure Description

[0019] Figure 1 This is a flowchart of the present invention.

[0020] Figure 2 This is a structural design drawing of an integrated compressor anti-surge vane casing suitable for additive manufacturing, according to the present invention.

[0021] Figure 3 This is a schematic diagram of the overall segmentation of the spoiler housing for additive manufacturing according to the present invention.

[0022] Figure 4 This is a schematic diagram showing the minimum powder quantity placement for selective laser melting metal 3D printing technology according to the present invention.

[0023] Figure 5 This is a design drawing of a supportless structure for a spoiler suitable for selective laser melting metal 3D printing technology according to the present invention.

[0024] Figure 6 This invention relates to a 3D printing support structure design for an integrated spoiler housing structure suitable for selective laser melting metal 3D printing technology. Detailed Implementation

[0025] The present invention will now be further described with reference to the accompanying drawings.

[0026] like Figure 1 The flowchart shown is a design method for additive manufacturing of compressor anti-surge spoiler casing for spatial irregular thin-walled structures. The method involves designing and obtaining the spoiler structure based on anti-surge performance, integrating the spoiler and connecting flange for structural integration and stability, effectively segmenting the casing based on the size constraints and placement characteristics of the additive manufacturing equipment, obtaining a segmented casing structure, reducing the weight and material of the heavy connecting flange while meeting strength requirements, and optimizing the placement of the spoiler by ensuring all functional surfaces are formed without support and minimizing powder application during one-time molding. Finally, the additive manufacturing of the compressor anti-surge spoiler casing for spatial irregular thin-walled structures is carried out.

[0027] like Figure 2The integrated design of the spatially shaped thin-walled spoiler housing shown is composed of an integrated design of the unit's inlet flange 1, the unit's outlet flange 2, and the shaped spoiler 6. It also includes rectangular cavities 4 for the unit's inlet side 3 and outlet side flanges. The cavity design improves printing efficiency and saves powder material, while the small cross-section printing further reduces the risk of deformation leading to printing failure. It also includes threaded holes 5 connecting the spoiler housing to the outer housing.

[0028] like Figure 3 The diagram shows the overall segmentation of the spoiler housing for additive manufacturing. The spoiler housing is divided into N segments to facilitate selective laser melting of metal for 3D printing. The segmentation design uses faces 1' and 3' along the mounting angle of the spoiler inlet end, and faces 2' and 4' along the mounting angle of the spoiler outlet end, to divide the overall annular spoiler housing into several sub-blocks circumferentially.

[0029] like Figure 4 The minimum powder placement position shown is suitable for selective laser melting metal 3D printing technology, which achieves the minimum height of the printing space and thus realizes high efficiency for each print.

[0030] like Figure 5 The spoiler structure shown is a supportless design for all functional surfaces of the spoiler, which is suitable for selective laser melting metal 3D printing technology. The angle range between the profile of each cross section of the irregular spoiler structure from the air intake side to the air outlet side of the unit and the printing horizontal reference is from α to β, which is within the safe range of the supportless design. This realizes the supportless design for printing the functional surfaces of the spoiler and ensures the surface quality of the printed spoiler.

[0031] like Figure 6 The integrated spoiler housing structure shown is a solid support design for selective laser melting metal 3D printing technology. The triangular grooves in the solid design meet the conditions for direct molding, which realizes the stability of the support and uniform heat transfer of the parts during the 3D printing process, and effectively ensures the smooth progress of the printing process.

[0032] Compared with the existing spoiler-type anti-surge casing structure, this invention fundamentally avoids the assembly and welding of parts and components, effectively improving the processing efficiency of such parts and achieving lightweighting and reliability.

[0033] The main process of this invention includes: integrating the spatial irregular thin-walled spoiler and the two axially connected end flanges into a single design, wherein the spoiler and the connecting end flanges are connected and smoothly transitioned through transition fillets; dividing the spoiler casing according to the processing size characteristics and placement characteristics of the additive manufacturing equipment; performing the required weight reduction and material reduction design on the divided substructures; performing additive manufacturing placement optimization design after completion to achieve the goal of having no support on the surface of the spoiler functional structure and saving the maximum amount of material per processing; and finally completing the additive manufacturing process according to the designed additive manufacturing structure model.

[0034] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An additive manufacturing design method for a compressor anti-surge spoiler casing for a spatially irregular thin-walled structure, characterized in that, Includes the following steps: Step 1: Combining the characteristics of selective laser melting metal additive manufacturing process and the structural features of the compressor anti-surge spoiler casing with a spatial irregular thin-walled structure, selective laser melting metal 3D printing technology and process are used to design and manufacture the compressor. Step 2: The compressor anti-surge turbulence vane casing is designed and controlled through structural design in additive manufacturing, resulting in a highly integrated, lightweight, and unsupported functional surfaces. Step 3: The anti-surge baffle in the compressor housing is designed as an integrated structure with its axial end flange. The baffle and the end flange are connected and transitioned through rounded corners, completely avoiding the assembly and connection of multiple parts. Step 4: Divide the compressor anti-surge spoiler housing from Step 3 along the installation angles of the spoilers on the inlet and outlet sides. In the division design, use surfaces 1' and 3' along the installation angle of the spoiler inlet end, and surfaces 2' and 4' along the installation angle of the spoiler outlet end, to divide the overall annular spoiler housing into several sub-blocks in the circumferential direction, so as to realize the segmented simultaneous printing of selective laser melting metal 3D printing in a limited forming platform; Step 5: The internal design of the flange connecting the two axial ends of the compressor anti-surge baffle in Step 4 is a regular discontinuous rectangular cavity structure to achieve the purpose of weight reduction and material reduction. At the same time, small cross-section printing further reduces the risk of deformation and failure during the printing process. Step 6: Perform additive manufacturing placement optimization design on the segmented spoiler housing formed in Step 4 and Step 5. Analyze and design that the forming angles α to β of all spoiler functional surfaces should be within the range of additive manufacturing self-forming without support, and the amount of powder used in one-time forming for rapid prototyping should be minimized. Step 7: The angle between the thin-walled spoiler structure with the spatial irregular surface and the reference plane of the selective laser melting metal 3D printing meets the unsupported design requirements in the manufacturing process. If it is necessary to adjust the original design twist direction of the spoiler during placement, the anti-surge performance needs to be recalculated after adjustment. If the design requirements are not met, the twist direction of the spoiler needs to be redesigned in combination with the angular direction required by additive manufacturing, and the work of steps 1 to 6 is repeated.

2. The additive manufacturing design method for a compressor anti-surge vane casing for a spatial irregular thin-walled structure according to claim 1, characterized in that, In step 1, the selective laser melting metal 3D printing is achieved by designing and manufacturing the spoiler housing in a segmented manner. The spoiler housing ring is divided into sections based on the molding dimensions of the additive manufacturing equipment and the requirement of unsupported design for all functional surfaces of the spoiler.

3. The additive manufacturing design method for a compressor anti-surge vane casing for a spatial irregular thin-walled structure according to claim 1, characterized in that, The anti-surge turbulence housing and the support connection structure of the selective laser melting metal 3D printing substrate are both designed as triangular groove-shaped solid structures to achieve unsupported one-time molding of all functional surfaces and stable additive manufacturing molding.

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