Advanced civil turboshaft engine special process control and verification method based on airworthiness requirements

Abstract

The invention discloses an advanced civil turboshaft engine special process control and verification method based on airworthiness requirements. The method comprises the following steps: S1, establishing a special process identification criterion to carry out special process identification on a civil turboshaft engine; s2, grading the special process according to the influence and the importance degree; s3, preliminarily establishing a special process specification, and forming a special process specification pre-batch draft by adopting a simulation piece and a process test; s4, after a special process specification pre-batch draft is formed, special process specification verification is carried out on trial production evaluation through screening suppliers; s5, after trial production evaluation is passed, different batches and different levels of test verification or complete machine comparison tests are carried out on different levels of special processes, and a special process specification formal approval draft is formed after passing of the test verification or complete machine comparison tests; s6, special process identification is completed through a special process extension complete machine test and an outer field long-time flight test. The control and verification requirements of a special process are met, the verification cost is low, and the result is reliable.

Description

Technical Field

[0001] The present application relates to the field of engine technology, and in particular, to a special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements. Background Art

[0002] During the airworthiness certification of turboshaft engines, the authority focuses on special processes when reviewing the engine manufacturing process. Carrying out and completing special process appraisal work can well demonstrate that the special process meets the "33.15 Materials" clause requirements of CCAR-33R2. However, there is no clear and comprehensive guiding method for how the special process appraisal work should be carried out, what it should include, and whether it can meet the airworthiness requirements.

[0003] In the early stage of civil turboshaft engine certification, no additional work was carried out in terms of special process control and verification. Special process control was mostly relied on in combination with usage experience to illustrate the airworthiness compliance of special processes. Therefore, it has the following shortcomings: a) The establishment of the existing special process airworthiness compliance verification method / process is not based on the interpretation of airworthiness regulations, cannot fully meet the airworthiness requirements, and cannot support the special process airworthiness compliance verification; b) Existing special process control and verification focus more on the control during the actual process implementation, such as requirements for operators, equipment, environment, etc., but have not systematically established a full-process special process control and verification process that includes technical requirements and management requirements; c) The existing special process control and verification are insufficient, the supporting data for the establishment of special process specifications are insufficient, and the verification of special process specifications is insufficient, which cannot well demonstrate the airworthiness compliance of special processes. Summary of the invention

[0004] The present application provides a special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements to address the technical problems that existing special process airworthiness compliance verification methods cannot fully meet airworthiness requirements, lack a full-process special process control and verification process, and insufficient verification cannot well demonstrate the airworthiness compliance of special processes.

[0005] This application is implemented through the following scheme: A special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements, comprising the steps of: S1. Establish special process identification criteria and conduct special process identification for civil turboshaft engines; S2. Classify the identified special processes into levels according to the degree of influence of civil turboshaft engine parts and the importance of civil turboshaft engine parts, and the levels include general level, important level and critical level; S3. Preliminary establishment of special process specifications, and use of simulation parts and process tests to carry out different batches of test verification and optimization of special process specifications of different levels to form a pre-approval draft of special process specifications; S4. After the pre-approval draft of the special process specification is formed, the special process specification verification is carried out by screening and conducting trial production evaluation of different batches of special processes of different levels; S5. After passing the trial production evaluation, different batches and different test verification levels of special processes of different levels are tested and verified, and after passing, mass production and result evaluation are carried out, or a certified engine with the same or similar special process as the engine to be verified is selected to carry out whole machine comparative test and evaluation; then, the environmental adaptability of the parts with special processes in the expected service environment is evaluated using simulation software, and after passing, a formal approval draft of the special process specification is formed. The test verification levels include material level, component level and whole machine level; S6. After the formally approved draft of the special process specification is formed, long-term whole-machine tests and long-term outdoor flight tests of different durations will be carried out on special processes of different levels, or flight tests based on artificial intelligence will be adopted. After the completion of the appraisal, the airworthiness compliance of the special process can be demonstrated and the special process will have completed the preliminary appraisal.

[0006] Furthermore, the step S1 specifically includes the steps of: S11. Interpret the airworthiness standards for aircraft engines and establish special process identification criteria based on relevant advisory circulars, special process control and verification experience of certified models, and experience of other models; S12. Perform special process identification on civil turboshaft engines according to established special process identification criteria.

[0007] Furthermore, the step S3 specifically includes the steps of: S31. Research process parameters, process methods, and process equipment, learn from similar process experience, and manage personnel qualifications and equipment capabilities, propose corresponding management requirements, and preliminarily select relevant process parameters and process procedures; S32. After the relevant process parameters and process procedures are initially selected, the environmental parameters under the corresponding environmental conditions are obtained according to the expected service environment of the engine. The environment-operating condition test spectrum is compiled according to the expected service location ratio and parking working time ratio of the engine to carry out environmental adaptability test assessment of a set duration. At the same time, simulation analysis is carried out under the same conditions, and the results of the environmental adaptability test assessment are used to correct the simulation analysis results. After correction, the simulation software is used to carry out the environmental adaptability assessment of the special process during the calendar life period. If it does not meet the design requirements, the special process needs to be optimized; S33. After the relevant process parameters and process procedures are initially selected and the environmental adaptability is evaluated to meet the design requirements, a preliminary draft of the special process specification is formed and simulation parts and process tests are used to carry out different batches of tests to verify and optimize special process specifications of different levels to form a pre-approved draft of the special process specification.

[0008] Furthermore, the step S32 specifically includes the steps of: S321. For general-level special processes, 1 furnace and 3 batches of simulated parts tests need to be carried out; for important-level special processes, 3 furnaces and 10 batches of simulated parts tests need to be carried out; for key-level special processes, 10 furnaces and 10 batches of simulated parts tests need to be carried out; S322. After completing the test verification, if it passes, it is preliminarily judged that the requirements of the special process specification are reasonable, thus forming a pre-approved draft of the special process specification. If it fails, it means that there are unreasonable requirements in the special process specification, then after optimization, the process test of the simulation part will be re-conducted until it passes and forms a pre-approved draft of the special process specification.

[0009] Furthermore, the step S4 specifically includes the steps of: S41. After the pre-approval draft of the special process specification is formed, the special process supplier screening is carried out. At least two suppliers are selected for each special process, and the personnel, equipment, raw materials, process capabilities, and production bases of each supplier are reviewed; S42. General-level special processes need to conduct trial production evaluation of one furnace and one batch, important-level special processes need to conduct trial production evaluation of one furnace and three batches, and key-level special processes need to conduct trial production evaluation of three furnaces and three batches, and carry out special process specification verification.

[0010] Furthermore, in step S41, when screening special process suppliers, general-level special process suppliers will enter the trial production evaluation step after passing the review. Important-level and key-level processes also need to review the historical production data of the special process, including process procedures, process parameters, and test data. Only after passing the review will they enter the trial production evaluation step.

[0011] Furthermore, the step S5 specifically includes the steps of: S501. After passing the trial production evaluation, the supplier shall carry out the first piece / batch production, and carry out test verification of different batches and different test verification levels for special processes of different levels. Among them, the general-level special process is 1 batch per furnace, the important-level special process is 3 batches per 3 furnaces, and the key-level special process is 10 batches per 10 furnaces; the different test verification levels are: the general-level special process only carries out material-level test verification, the important-level special process carries out material-level and component-level test verification, and the key-level special process carries out material-level, component-level and whole machine-level test verification. Among them, the whole machine-level test verification of the key-level special process must pass the endurance test verification of the whole machine for at least 150 hours; S502. After completing the test verification and passing it, carry out mass production and result evaluation; S503. Use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include but are not limited to: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After the simulation evaluation, the special process specification is formally approved. After passing the evaluation, it is formally approved as the official draft of the special process specification.

[0012] Furthermore, in step S501: Material-level test verification is based on the requirements of special process specifications. Depending on the level of the special process, additional verification items are added as appropriate, including coating thickness, shear strength, and weld length; Component-level test verification projects select test items with different assessment intensities according to the different levels of special processes, including static test, pressure test, and thermal shock test; The whole machine level test verification project selects test items with different assessment intensities according to the different levels of special processes, including 1000h low cycle, 150h endurance test, corrosion resistance test, and rotor structure completion test.

[0013] Furthermore, the step S5 specifically includes the steps of: S511. Select certified engines whose operating conditions can cover the engines to be verified and whose special processes are the same or similar. Carry out whole-machine tests including 150-hour endurance tests. After the whole-machine tests are completed, compare and analyze the parts containing the special processes of the two engines after the tests are completed. If the test results are equivalent, it is considered that the special process under test has passed the test verification. S512. After completing the whole machine comparison test, use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After passing the evaluation, it will be officially approved as the official draft of the special process specification.

[0014] Furthermore, the step S6 specifically includes the steps of: S61. After the formal approval draft of the special process specification is formed, at least 2,000 low-cycle long-term whole-machine test verifications shall be carried out for the important and key-level special processes; after the long-term whole-machine test verification is completed, the key-level special processes shall be verified by long-term field flight tests; Alternatively, flight testers / robots can be used to replace test pilots to conduct test flights under harsh and extreme conditions, and accelerated assessment task spectra can be compiled to assess the performance of special processes under extreme conditions. Through the accelerated equivalent relationship, the life of special processes in the expected service environment can be given to evaluate whether they meet the design requirements; S62. After completing the above verification, the special process is identified, and the completion of the identification indicates the airworthiness compliance of the special process.

[0015] Compared with the prior art, this application has the following beneficial effects: a) This application comprehensively and systematically establishes the control and verification methods for the airworthiness compliance of special processes, filling the gap of the lack of control and verification methods / processes that meet airworthiness requirements for special processes; b) This application has formulated different work items for special processes at different levels, which can effectively reduce verification work, reduce verification costs, and shorten verification cycles while ensuring the reliability of special processes; c) The innovative long-term field test flight assessment of special processes proposed in this application can effectively ensure the reliability of special processes; d) It proposes the work items, work processes and work contents that need to be carried out, which can well support the special process control and verification work of civil turboshaft engines and meet the airworthiness requirements.

[0016] In addition to the above-described purposes, features and advantages, the present application also has other purposes, features and advantages. The present application will be further described in detail with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application: Figure 1 It is a schematic flow chart of a special process control and verification method for an advanced civil turboshaft engine based on airworthiness requirements in a preferred embodiment of the present application; Figure 2 is a schematic flow chart of the sub-steps of step S1; Figure 3 is a schematic flow chart of sub-steps of step S3; Figure 4 is a schematic flow chart of sub-steps of step S32; Figure 5 is a schematic flow chart of sub-steps of step S4; Figure 6 is a schematic flow chart of sub-steps of step S5; Figure 7 is another sub-step flow chart of step S5; Figure 8 It is a schematic diagram of the sub-step flow chart of step S6. DETAILED DESCRIPTION

[0018] The embodiments of the present application are described in detail below in conjunction with the accompanying drawings, but the present application can be implemented in a variety of different ways defined and covered below.

[0019] like Figure 1 As shown, the preferred embodiment of the present application provides a special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements, comprising the steps of: S1. Establish special process identification criteria and conduct special process identification for civil turboshaft engines; S2. Classify the identified special processes into levels according to the degree of influence of civil turboshaft engine parts and the importance of civil turboshaft engine parts, and the levels include general level, important level and critical level; S3. Preliminary establishment of special process specifications, and use of simulation parts and process tests to carry out different batches of test verification and optimization of special process specifications of different levels to form a pre-approval draft of special process specifications; S4. After the pre-approval draft of the special process specification is formed, the special process specification verification is carried out by screening and conducting trial production evaluation of different batches of special processes of different levels; S5. After passing the trial production evaluation, different batches and different test verification levels are tested and verified for special processes of different levels. After passing, mass production and result evaluation are carried out, or a certified engine with the same or similar special process as the engine to be verified is selected to carry out whole machine comparative test and evaluation; then, the environmental adaptability of the parts with special processes in the expected service environment is evaluated using simulation software. After passing, the formal approval draft of the special process specification is formed. The test verification levels include material level, component level and whole machine level; S6. After the formally approved draft of the special process specification is formed, long-term whole-machine tests and long-term outdoor flight tests of different durations will be carried out on special processes of different levels, or flight tests based on artificial intelligence will be adopted. After the completion of the appraisal, the airworthiness compliance of the special process can be demonstrated and the special process will have completed the preliminary appraisal.

[0020] Compared with the prior art, the special process control and verification method of advanced civil turboshaft engines based on airworthiness requirements of this embodiment has the following beneficial effects: a) This embodiment comprehensively and systematically establishes the control and verification methods for the airworthiness compliance of special processes, filling the gap of the lack of control and verification methods / processes that meet airworthiness requirements for special processes; b) This embodiment formulates different work items for special processes at different levels, which can effectively reduce verification work, reduce verification costs, and shorten verification cycles while ensuring the reliability of special processes; c) The innovative long-time field test flight assessment of special processes proposed in this embodiment can effectively ensure the reliability of special processes; d) This embodiment proposes the work items, work processes and work contents that need to be carried out, which can well support the special process control and verification work of civil turboshaft engines and meet the airworthiness requirements.

[0021] Preferably, if Figure 2 As shown, the step S1 specifically includes the steps of: S11. Interpret the airworthiness standards for aircraft engines and establish special process identification criteria based on relevant advisory circulars, special process control and verification experience of certified models, and experience of other models; S12. Perform special process identification on civil turboshaft engines according to established special process identification criteria.

[0022] When establishing the special process identification criteria, this embodiment interprets the aircraft engine airworthiness standards, such as the "Aircraft Engine Airworthiness Standards" and "33.15 Materials" of (CCAR-33R2), and combines relevant advisory circulars, special process control and verification experience of certified models, and experience of other models to comprehensively establish special process identification criteria, thereby ensuring the accuracy and reliability of special process identification and providing an initial basis for subsequent test verification of different batches and different test verification levels.

[0023] Preferably, if Figure 3 As shown, the step S3 specifically includes the steps of: S31. Research process parameters, process methods, and process equipment, learn from similar process experience, and manage personnel qualifications and equipment capabilities, propose corresponding management requirements, and preliminarily select relevant process parameters and process procedures; S32. After the relevant process parameters and process procedures are initially selected, the environmental parameters under the corresponding environmental conditions are obtained according to the expected service environment of the engine. The environment-operating condition test spectrum is compiled according to the expected service location ratio and parking working time ratio of the engine to carry out environmental adaptability test assessment of a set duration. At the same time, simulation analysis is carried out under the same conditions, and the results of the environmental adaptability test assessment are used to correct the simulation analysis results. After correction, the simulation software is used to carry out the environmental adaptability assessment of the special process during the calendar life period. If it does not meet the design requirements, the special process needs to be optimized; S33. After the relevant process parameters and process procedures are initially selected and the environmental adaptability is evaluated to meet the design requirements, a preliminary draft of the special process specification is formed and simulation parts and process tests are used to carry out different batches of tests to verify and optimize special process specifications of different levels to form a pre-approved draft of the special process specification.

[0024] On the one hand, this embodiment studies process parameters, process methods, and process equipment, draws on similar process experience, and at the same time manages and controls personnel qualifications and equipment capabilities, proposes corresponding management requirements, and preliminarily selects relevant process parameters and process procedures; on the other hand, after the relevant process parameters, process procedures, etc. are preliminarily selected to form a preliminary draft of the special process specification, simulation parts and process tests are used to carry out different batches of test verification and optimization of special process specifications of different levels to form a pre-approved draft of the special process specification. Its purposes and benefits include: managing and controlling personnel qualifications and equipment capabilities is a necessary condition for product stability control, simulation parts can simulate typical stress distribution forms, structural forms, etc. of parts, and can quickly and cost-effectively verify typical parts of parts that need to be focused on for verification.

[0025] Preferably, if Figure 4 As shown, the step S32 specifically includes the steps of: S321. For general-level special processes, 1 furnace and 3 batches of simulated parts tests need to be carried out; for important-level special processes, 3 furnaces and 10 batches of simulated parts tests need to be carried out; for key-level special processes, 10 furnaces and 10 batches of simulated parts tests need to be carried out; S322. After completing the test verification, if it passes, it is preliminarily judged that the requirements of the special process specification are reasonable, thus forming a pre-approved draft of the special process specification. If it fails, it means that there are unreasonable requirements in the special process specification, then after optimization, the process test of the simulation part will be re-conducted until it passes and forms a pre-approved draft of the special process specification.

[0026] In this embodiment, when forming a preliminary draft of a special process specification, simulation part tests of different numbers of furnaces and batches are carried out according to different levels of special processes to verify whether the corresponding special process specifications are reasonable, and a preliminary draft of the special process specification is formed when it is reasonable, and when it is unreasonable, the process test of the simulation parts is re-conducted after optimization until it is formed after passing the preliminary draft of the special process specification. Its purposes and benefits include: the higher the level of the special process, the more serious the consequences of failure are, and a higher probability of meeting the design requirements is required, so more furnace and batch data are needed to prove the stability of the special process, but if all processes are verified in large quantities, the development cost will increase, so a corresponding number of verifications are carried out according to the different levels of the special process to minimize the verification cost.

[0027] Preferably, if Figure 5As shown, the step S4 specifically includes the steps of: S41. After the pre-approval draft of the special process specification is formed, the special process supplier screening is carried out. At least two suppliers are selected for each special process, and the personnel, equipment, raw materials, process capabilities, and production bases of each supplier are reviewed; S42. General-level special processes need to conduct trial production evaluation of one furnace and one batch, important-level special processes need to conduct trial production evaluation of one furnace and three batches, and key-level special processes need to conduct trial production evaluation of three furnaces and three batches, and carry out special process specification verification.

[0028] After forming the preliminary draft of the special process specification, this embodiment first screens the suppliers of the special process through comprehensive considerations to preliminarily ensure that the special process provided by the supplier can meet the requirements of the process specification; then, according to the different levels of the special process, the supplier conducts trial production evaluations of different numbers of furnaces and batches to verify whether the special process specification is reasonable, and further realizes efficient and reliable specification verification of the special process. Its purposes and benefits include: through comprehensive considerations, the supplier can be preliminarily selected from the aspects of qualifications, etc., according to the different levels of the special process, the supplier conducts trial production evaluations of different numbers of furnaces and batches to verify whether the special process specification is reasonable, which can reduce the verification cost and cycle.

[0029] Preferably, in step S41, when screening special process suppliers, general-level special process suppliers enter the trial production evaluation step after passing the review, and important-level and key-level processes also need to review the historical production data of the special process, including process procedures, process parameters, and test data. Only after passing the review can they enter the trial production evaluation step. Its purpose and benefits include: the general-level special process supplier can be quickly selected, and the capabilities of important and key-level special process suppliers can also be strictly assessed to reduce research and development risks.

[0030] Preferably, if Figure 6 As shown, the step S5 specifically includes the steps of: S501. After passing the trial production evaluation, the supplier shall carry out the first piece / batch production, and carry out test verification of different batches and different test verification levels for special processes of different levels. Among them, the general-level special process is 1 batch per furnace, the important-level special process is 3 batches per 3 furnaces, and the key-level special process is 10 batches per 10 furnaces; the different test verification levels are: the general-level special process only carries out material-level test verification, the important-level special process carries out material-level and component-level test verification, and the key-level special process carries out material-level, component-level and whole machine-level test verification. Among them, the whole machine-level test verification of the key-level special process must pass the endurance test verification of the whole machine for at least 150 hours; S502. After completing the test verification and passing it, carry out mass production and result evaluation; S503. Use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include but are not limited to: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After the simulation evaluation, the special process specification is formally approved. After passing the evaluation, it is formally approved as the official draft of the special process specification.

[0031] In this embodiment, after the trial production evaluation, the supplier carries out the first piece / batch production work, and carries out test verification of different batches and different test verification levels for special processes of different levels, such as 1 batch of 1 furnace for general-level special processes, 3 batches of 3 furnaces for important-level special processes, and 10 batches of 10 furnaces for key-level special processes. After the test verification is completed, the process capability index Cpk is calculated to verify the stability of the special process. The general-level special process only carries out material-level test verification, the important-level special process carries out material-level and component-level test verification, and the key-level special process carries out material-level, component-level and whole-machine-level test verification. Its purpose and benefits include: the higher the level of special process, the more serious the consequences of failure are, and a higher probability of compound design requirements is required, so more furnace batch data are needed to prove the stability of the special process, but if all processes are verified in large quantities, the development cost will increase, so verification of the corresponding batch number and test verification level is carried out according to the different levels of special processes to minimize the verification cost.

[0032] Preferably, in step S501: Material-level test verification is based on the requirements of special process specifications. Depending on the level of the special process, additional verification items are added as appropriate, including coating thickness, shear strength, and weld length; Component-level test verification projects select test items with different assessment intensities according to the different levels of special processes, including static test, pressure test, and thermal shock test; The whole machine level test verification project selects test items with different assessment intensities according to the different levels of special processes, including 1000h low cycle, 150h endurance test, corrosion resistance test, and rotor structure completion test.

[0033] In this embodiment, material-level test verification, component-level test verification, and whole-machine-level test verification items can be selected according to the level of the process, and their purposes and benefits include: reducing the verification cycle, reducing the verification cost, etc.

[0034] Preferably, if Figure 7 As shown, the step S5 specifically includes the steps of: S511. Select certified engines whose operating conditions can cover the engines to be verified and whose special processes are the same or similar. Carry out whole-machine tests including 150-hour endurance tests. After the whole-machine tests are completed, compare and analyze the parts containing the special processes of the two engines after the tests are completed. If the test results are equivalent, it is considered that the special process under test has passed the test verification. S512. After completing the whole machine comparison test, use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After passing the evaluation, it will be officially approved as the official draft of the special process specification.

[0035] This embodiment adopts a whole-machine comparison test to verify the special process, which can complete the verification work in a short period of time and reduce the verification cost and time.

[0036] Preferably, if Figure 7 As shown, step S6 specifically includes the steps of: S61. After the formal approval draft of the special process specification is formed, at least 2,000 low-cycle long-term whole-machine test verifications shall be carried out for the important and key-level special processes; after the long-term whole-machine test verification is completed, the key-level special processes shall be verified by long-term field flight tests; Alternatively, to shorten the test cycle and reduce the test risk of test pilots, flight testers / robots are used to replace test pilots to carry out test flights under harsh and extreme conditions, and accelerated assessment task spectra are compiled to assess the performance of special processes under extreme conditions. Through the accelerated equivalent relationship, the life of the special process in the expected service environment is given to evaluate whether it meets the design requirements; S62. After completing the above verification, the special process is identified, and the completion of the identification indicates the airworthiness compliance of the special process.

[0037] After the formally approved draft of the special process specification is formed, this embodiment conducts long-term whole machine tests and outdoor long-term flight tests of different durations for special processes of different levels, or uses flight testers / robots to replace test pilots to complete special process identification. Among them, during the long-term whole machine test verification, the general-level special process can cut this test, and only the important-level and key-level special processes must carry out at least 2000 low-cycle tests; after completing the whole machine test, a long-term field flight test is carried out, and the general-level and important-level special processes can cut this test, and only the key-level special processes must carry out outdoor long-term flight verification, which not only ensures the efficiency of the special process identification, but also effectively ensures the reliability of the special process identification.

[0038] To sum up, the special process control and verification method for advanced civil turboshaft engines proposed in the above embodiments of the present application ensures that the special process of the turboshaft engine meets the "33.15 Materials" clause requirements of CCAR-33R2, and proposes the work items, work processes and work connotations that need to be carried out, which can well support the civil turboshaft engine to carry out special process control and verification work and meet airworthiness requirements.

[0039] Although the preferred embodiments of the present application have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0040] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

Claims

1. A special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements, characterized in that: Includes steps: S1. Establish special process identification criteria and conduct special process identification for civil turboshaft engines; S2. Classify the identified special processes into levels according to the degree of influence of civil turboshaft engine parts and the importance of civil turboshaft engine parts, and the levels include general level, important level and critical level; S3. Preliminary establishment of special process specifications, and use of simulation parts and process tests to carry out different batches of test verification and optimization of special process specifications of different levels to form a pre-approval draft of special process specifications; S4. After the pre-approval draft of the special process specification is formed, the special process specification verification is carried out by screening and conducting trial production evaluation of different batches of special processes of different levels; S5. After passing the trial production evaluation, different batches and different test verification levels of special processes of different levels are tested and verified, and after passing, mass production and result evaluation are carried out, or a certified engine with the same or similar special process as the engine to be verified is selected to carry out whole machine comparative test and evaluation; then, the environmental adaptability of the parts with special processes in the expected service environment is evaluated using simulation software, and after passing, a formal approval draft of the special process specification is formed. The test verification levels include material level, component level and whole machine level; S6. After the formally approved draft of the special process specification is formed, long-term whole-machine tests and long-term outdoor flight tests of different durations will be carried out on special processes of different levels, or flight tests based on artificial intelligence will be adopted. After the completion of the appraisal, the airworthiness compliance of the special process can be demonstrated and the special process will have completed the preliminary appraisal.

2. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 1 is characterized in that: The step S1 specifically includes the following steps: S11. Interpret the airworthiness standards for aircraft engines and establish special process identification criteria based on relevant advisory circulars, special process control and verification experience of certified models, and experience of other models; S12. Perform special process identification on civil turboshaft engines according to established special process identification criteria.

3. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 1 is characterized in that: The step S3 specifically comprises the following steps: S31. Research process parameters, process methods, and process equipment, learn from similar process experience, and manage personnel qualifications and equipment capabilities, propose corresponding management requirements, and preliminarily select relevant process parameters and process procedures; S32. After the relevant process parameters and process procedures are initially selected, the environmental parameters under the corresponding environmental conditions are obtained according to the expected service environment of the engine. The environment-operating condition test spectrum is compiled according to the expected service location ratio and parking working time ratio of the engine to carry out environmental adaptability test assessment of a set duration. At the same time, simulation analysis is carried out under the same conditions, and the results of the environmental adaptability test assessment are used to correct the simulation analysis results. After correction, the simulation software is used to carry out the environmental adaptability assessment of the special process during the calendar life period. If it does not meet the design requirements, the special process needs to be optimized; S33. After the relevant process parameters and process procedures are initially selected and the environmental adaptability is evaluated to meet the design requirements, a preliminary draft of the special process specification is formed and simulation parts and process tests are used to carry out different batches of tests to verify and optimize special process specifications of different levels to form a pre-approved draft of the special process specification.

4. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 3 is characterized in that: The step S32 specifically includes the following steps: S321. For general-level special processes, 1 furnace and 3 batches of simulated parts tests need to be carried out; for important-level special processes, 3 furnaces and 10 batches of simulated parts tests need to be carried out; for key-level special processes, 10 furnaces and 10 batches of simulated parts tests need to be carried out; S322. After completing the test verification, if it passes, it is preliminarily judged that the requirements of the special process specification are reasonable, thus forming a pre-approved draft of the special process specification. If it fails, it means that there are unreasonable requirements in the special process specification, then after optimization, the process test of the simulation part will be re-conducted until it passes and forms a pre-approved draft of the special process specification.

5. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 1 is characterized in that: The step S4 specifically comprises the following steps: S41. After the pre-approval draft of the special process specification is formed, the special process supplier screening is carried out. At least two suppliers are selected for each special process, and the personnel, equipment, raw materials, process capabilities, and production bases of each supplier are reviewed; S42. General-level special processes need to conduct trial production evaluation of one furnace and one batch, important-level special processes need to conduct trial production evaluation of one furnace and three batches, and key-level special processes need to conduct trial production evaluation of three furnaces and three batches, and carry out special process specification verification.

6. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 5 is characterized in that: In step S41, when screening special process suppliers, general-level special process suppliers will enter the trial production evaluation step after passing the review. Important-level and key-level processes also need to review the historical production data of the special process, including process procedures, process parameters, and test data. Only after passing the review will they enter the trial production evaluation step.

7. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 1 is characterized in that: The step S5 specifically includes the following steps: S501. After passing the trial production evaluation, the supplier shall carry out the first piece / batch production, and carry out test verification of different batches and different test verification levels for special processes of different levels. Among them, the general-level special process is 1 batch per furnace, the important-level special process is 3 batches per 3 furnaces, and the key-level special process is 10 batches per 10 furnaces; the different test verification levels are: the general-level special process only carries out material-level test verification, the important-level special process carries out material-level and component-level test verification, and the key-level special process carries out material-level, component-level and whole machine-level test verification. Among them, the whole machine-level test verification of the key-level special process must pass the endurance test verification of the whole machine for at least 150 hours; S502. After completing the test verification and passing it, carry out mass production and result evaluation; S503. Use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include but are not limited to: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After the simulation evaluation, the special process specification is formally approved. After passing the evaluation, it is formally approved as the official draft of the special process specification.

8. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 7 is characterized in that: In step S501: Material-level test verification is based on the requirements of special process specifications. Depending on the level of the special process, additional verification items are added as appropriate, including coating thickness, shear strength, and weld length; Component-level test verification projects select test items with different assessment intensities according to the different levels of special processes, including static test, pressure test, and thermal shock test; The whole machine level test verification project selects test items with different assessment intensities according to the different levels of special processes, including 1000h low cycle, 150h endurance test, corrosion resistance test, and rotor structure completion test.

9. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 7 is characterized in that: The step S5 specifically includes the following steps: S511. Select certified engines whose operating conditions can cover the engines to be verified and whose special processes are the same or similar. Carry out whole-machine tests including 150-hour endurance tests. After the whole-machine tests are completed, compare and analyze the parts containing the special processes of the two engines after the tests are completed. If the test results are equivalent, it is considered that the special process under test has passed the test verification. S512. After completing the whole machine comparison test, use simulation software to evaluate the environmental adaptability of special process parts in the expected service environment. The evaluation items include: salt spray corrosion, dust erosion, extreme cold environment, hot salt corrosion. After passing the evaluation, it will be officially approved as the official draft of the special process specification.

10. The special process control and verification method for advanced civil turboshaft engines based on airworthiness requirements according to claim 1, characterized in that: The step S6 specifically comprises the following steps: S61. After the formal approval draft of the special process specification is formed, at least 2,000 low-cycle long-term whole-machine tests shall be carried out for important and critical special processes; After completing the long-term whole-machine test verification, carry out long-term field flight test verification for key-level special processes; Alternatively, flight testers / robots can be used to replace test pilots to conduct test flights under harsh and extreme conditions, and accelerated assessment task spectra can be compiled to assess the performance of special processes under extreme conditions. Through the accelerated equivalent relationship, the life of special processes in the expected service environment can be given to evaluate whether they meet the design requirements; S62. After completing the above verification, the special process is identified, and the completion of the identification indicates that the special process is airworthy.

Images