Machining process for guide vane of front-end steam compressor of gas turbine

Abstract

The invention relates to the technical field of guide vane machining processes, and discloses a gas turbine front end steam compressor guide vane machining process which comprises the following steps of three-dimensional modeling, numerical simulation, creation of structured grids, setting of boundary conditions and initial conditions of simulation, analysis of simulation results and manufacturing of vane samples for testing. The design of the guide blade is optimized, a mold structure is designed, a detailed machining program is compiled, and a product is detected by three-coordinate measuring equipment; through the processing technology, the performance of the blade can be predicted, then the design is optimized, the efficiency and durability of the blade are improved, the problem of time consumption caused by repeated modification of a mathematical model and generation of a computational grid in a traditional method is also avoided, and the subsequent processing efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of guide blade processing technology, and specifically relates to a processing technology for guide blades of a front-end steam compressor of a combustion engine. Background Art

[0002] The guide vanes of the steam compressor at the front end of the gas turbine are important components of the gas turbine. Their main function is to prevent compressor surge and adjust the exhaust temperature. The guide vanes are a key component of the gas turbine. They deflect the high-temperature and high-speed airflow ejected from the combustion chamber at a certain angle and rush toward the high-pressure and low-pressure blades of the turbine. The high-speed rotation of the turbine blades drives the compressor to rotate, perform a reciprocating cycle, and generate thrust.

[0003] In the traditional processing of the guide vanes of the front-end steam compressor of the gas turbine, due to the unique structure and complex shape of the compressor blades, it is easy to cause frequent digital model modifications when designing the blades, affecting the processing efficiency. Moreover, as a typical thin-walled part, the blades have high processing accuracy, which makes it difficult to generate computational grids. Due to the problems of digital model modification and computational grid generation, the processing efficiency and yield rate are further affected in the selection of tool materials, cutting parameters and the setting of tool feeding methods, resulting in unstable processing efficiency and processing quality.

[0004] For this purpose, we propose a processing technology for the guide vanes of the front-end steam compressor of the gas turbine. Summary of the invention

[0005] The purpose of the present invention is to provide a processing technology for the guide vanes of a front-end steam compressor of a gas engine in order to solve the above-mentioned problem.

[0006] The technical solution adopted by the present invention is as follows: A processing technology for a guide vane of a front-end steam compressor of a gas turbine, the processing technology comprising the following steps: S1: According to the design requirements and performance parameters of the guide vanes of the front-end steam compressor of the gas turbine, the basic shape, size and material of the guide vanes are determined, and the three-dimensional modeling of the vanes is performed using three-dimensional modeling software; S2: Use numerical simulation software to define the parameters required for simulation, such as material properties, processing speed, air flow speed, etc., according to actual processing and use conditions, to ensure that all parameters accurately reflect the actual situation to ensure the reliability of the simulation results; S3: Meshing the three-dimensional model of the guide vane, discretizing the model into a series of small units, and creating a structured grid; S4: Set the boundary conditions and initial conditions of the simulation, such as the temperature of the guide blade surface, the velocity of the airflow inlet, etc., define the boundary state of the calculation area, provide a clear physical environment for numerical simulation, and ensure the reliability and accuracy of the simulation results; S5: Use numerical simulation software to simulate the behavior of the guide vanes during processing and use according to the defined parameters, boundary conditions and initial conditions, and analyze the results of the simulation calculations to check whether there are any abnormalities or unexpected situations. Based on the analysis results, optimize the guide vane design to improve the performance and stability of the guide vanes. S6: Make blade samples, install them in wind tunnel test equipment, conduct wind tunnel tests under different conditions, including setting parameters such as wind speed and air pressure, observe and record the response of the blades under different conditions, such as torsion, bending and vibration, analyze according to the experimental data, and optimize the guide blade design to improve the performance and stability of the guide blades; S7: According to the optimized guide blade design, alloy steel or cemented carbide is selected, and the mold structure is designed according to the shape and size of the blade. The mold is heat treated to eliminate internal stress and increase service life. At the same time, the size and shape of the mold are inspected to ensure that its accuracy meets the requirements. Finally, the mold is tested and debugged to ensure its stability and reliability during the processing; S8: Prepare detailed machining procedures according to mold design, and use numerical simulation technology to predict and control cutting force, temperature distribution, etc. during machining; S9: Use high-precision three-dimensional coordinate measuring equipment to conduct a comprehensive inspection of the shape, size and position of the blades, and perform data analysis on the inspection results to ensure that the processing accuracy of the blades meets the requirements.

[0007] In a preferred embodiment of the invention, the guide vane is made of a material selected from high temperature alloys and nickel-based alloys.

[0008] In a preferred embodiment of the invention, the three-dimensional modeling software is any one of SolidWorks, UG or CATIA.

[0009] In a preferred embodiment of the invention, the numerical simulation software is any one of ANSYS and Fluent.

[0010] In a preferred embodiment of the invention, the boundary conditions are used to determine the variation patterns of the variables or their derivatives to be solved at the boundaries of the solution area with time and location.

[0011] In a preferred embodiment of the invention, the initial conditions are used to study the spatial distribution of various solution variables of the object at the beginning of the process.

[0012] In a preferred embodiment of the invention, the structured grid is used to provide high-quality input for subsequent numerical simulations, thereby facilitating understanding of the flow and heat transfer characteristics of airflow passing through the blades, predicting the performance of the guide vanes, and optimizing the design.

[0013] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. In the present invention, the blade design and optimization can be performed on a computer through modeling and numerical simulation, thus avoiding the time-consuming problem of repeatedly modifying the numerical model and generating the computational grid in the traditional method, and improving the subsequent processing efficiency.

[0014] 2. In the present invention, numerical simulation can be used to perform fluid-solid coupling analysis on blades with different cooling structures, compare their cooling effects, and thus select the best cooling solution, which is of great significance for improving the efficiency and service life of gas turbines.

[0015] 3. In the present invention, the three-dimensional model of the guide blade is gridded and discretized into a series of small units. Through grid division, a structured grid can be created. The structured grid can improve the accuracy of numerical simulation and more accurately reflect the flow of airflow on the blade surface. Through numerical simulation, the performance of the blade can be predicted, and then the design can be optimized to improve the efficiency and durability of the blade. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The present invention is a flowchart of the process for machining guide vanes of a front-end steam compressor of a gas engine. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in combination with the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] The following will be combined Figure 1 A processing technology for guide vanes of a front-end steam compressor of a gas turbine according to an embodiment of the present invention is described in detail.

[0019] Reference Figure 1 , Example

[0020] Reference Figure 1A processing technology for the guide vanes of the front-end steam compressor of a gas turbine, the processing technology includes the following steps: according to the design requirements and performance parameters of the guide vanes of the front-end steam compressor of the gas turbine, the basic shape, size and material of the guide vanes are determined, and the three-dimensional modeling software is used to perform three-dimensional modeling of the vanes. The three-dimensional modeling software is any one of SolidWorks, UG or CATIA. The manufacturing material of the guide vanes is any one of high-temperature alloys or nickel-based alloys; specifically, according to the performance parameters, suitable materials are selected for visualization analysis, which is also convenient for airflow analysis, structural strength analysis, etc., to discover potential problems in advance. According to the actual processing and use conditions, the numerical simulation software is any one of ANSYS or Fluent, and the parameters required for simulation, such as material properties, processing speed, airflow speed, etc., are defined to ensure that all parameters accurately reflect the actual situation to ensure the reliability of the simulation results.

[0021] Reference Figure 1 , the three-dimensional model of the guide vane is meshed, the model is discretized into a series of small units, and a structured grid is created; the structured grid is used to provide high-quality input for subsequent numerical simulations, so as to understand the flow and heat transfer characteristics of the airflow through the blades, predict the performance of the guide vanes, and optimize the design; specifically, the structured grid can improve the accuracy of numerical simulations and more accurately reflect the flow of airflow on the blade surface; through numerical simulations, the performance of the blades can be predicted, and then the design can be optimized to improve the efficiency and durability of the blades.

[0022] Reference Figure 1 , set the boundary conditions and initial conditions of the simulation, such as the temperature of the guide blade surface, the velocity of the airflow inlet, etc., define the boundary state of the calculation area, provide a clear physical environment for the numerical simulation, and ensure the reliability and accuracy of the simulation results; the boundary conditions are used to change the variables or their derivatives solved on the boundary of the solution area with time and place, and the initial conditions are used to study the spatial distribution of each solution variable of the object at the beginning of the process; specifically, reasonable boundary conditions can ensure that the simulation results are consistent with the actual physical phenomena and reduce errors; appropriate initial conditions help the simulation process to proceed smoothly and avoid non-physical fluctuations or divergences in the calculation process; clear boundary conditions make the simulation results easier to analyze and interpret, and also facilitate comparison and verification with experimental results, thereby improving the accuracy of the simulation, enhancing the stability of the simulation, and facilitating the analysis and verification of the results.

[0023] Reference Figure 1, use numerical simulation software to simulate the behavior of guide blades during processing and use according to defined parameters, boundary conditions and initial conditions, and analyze the results of simulation calculations to check whether there are any abnormalities or unexpected situations. According to the analysis results, the guide blade design is optimized to improve the performance and stability of the guide blades. Specifically, numerical simulation can be used to perform fluid-solid coupling analysis on blades with different cooling structures, compare their cooling effects, and thus select the best cooling solution, which is of great significance for improving the efficiency and service life of gas turbines. At the same time, through modeling numerical simulation, the blade design and optimization can be performed on the computer, avoiding the time-consuming problems caused by repeated modification of numerical models and generation of computational grids in traditional methods, thereby improving work efficiency. Reference Figure 1 , make blade samples, install the blade samples in wind tunnel testing equipment, and conduct wind tunnel tests under different conditions, including the setting of parameters such as wind speed and air pressure, observe and record the reactions of the blades under different conditions, such as torsion, bending and vibration, etc., analyze according to the experimental data, and optimize the guide blade design to improve the performance and stability of the guide blades; specifically, through testing, various conditions of the blades in the actual working environment, such as different wind speeds and air pressures, can be simulated to provide reliable data for blade performance evaluation; in the test, the torsion, bending and vibration of the blades under different conditions can be observed and recorded, which helps to fully understand the performance of the blades; based on the analysis of experimental data, the deficiencies in the blade design can be discovered, and then optimized to improve the performance and stability of the blades.

[0024] Reference Figure 1 According to the optimized guide blade design, alloy steel or cemented carbide is selected, and the mold structure is designed according to the shape and size of the blade. The mold is heat treated to eliminate internal stress and increase its service life. At the same time, the size and shape of the mold are inspected to ensure that its accuracy meets the requirements. Finally, the mold is tested and debugged to ensure its stability and reliability during the processing. Specifically, alloy steel or cemented carbide is selected to improve the high temperature resistance, wear resistance and oxidation resistance of the blade; the mold structure is designed according to the shape and size of the blade to ensure the strength and rigidity of the mold and increase its service life; the mold is heat treated and inspected to eliminate internal stress and ensure the accuracy of the size and shape of the mold; through trial molding and debugging, the stability and reliability of the mold during the processing are ensured to improve production efficiency.

[0025] Reference Figure 1, according to the mold design, a detailed processing procedure is compiled, and the numerical simulation technology is used to predict and control the cutting force, temperature distribution, etc. in the processing process; the high-precision three-coordinate measuring equipment is used to comprehensively detect the shape, size and position of the blade, and the test results are analyzed data to ensure that the processing accuracy of the blade meets the requirements; specifically, through numerical simulation technology, the cutting force, temperature distribution, etc. in the processing process are predicted and controlled, which helps to optimize processing parameters, reduce processing errors, and improve processing efficiency; the high-precision three-coordinate measuring equipment is used to comprehensively detect the shape, size and position of the blade, and the test results are analyzed data to ensure that the processing accuracy of the blade meets the design requirements and improve product quality.

[0026] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0027] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for machining guide vanes of a front-end steam compressor of a gas turbine, characterized in that: The processing technology includes the following steps: S1: According to the design requirements and performance parameters of the guide vanes of the front-end steam compressor of the gas turbine, the basic shape, size and material of the guide vanes are determined, and the three-dimensional modeling of the vanes is performed using three-dimensional modeling software; S2: Use numerical simulation software to define the parameters required for simulation, such as material properties, processing speed, air flow speed, etc., according to actual processing and use conditions, to ensure that all parameters accurately reflect the actual situation to ensure the reliability of the simulation results; S3: Meshing the three-dimensional model of the guide vane, discretizing the model into a series of small units, and creating a structured grid; S4: Set the boundary conditions and initial conditions of the simulation, such as the temperature of the guide blade surface, the velocity of the airflow inlet, etc., define the boundary state of the calculation area, provide a clear physical environment for numerical simulation, and ensure the reliability and accuracy of the simulation results; S5: Use numerical simulation software to simulate the behavior of the guide vanes during processing and use according to the defined parameters, boundary conditions and initial conditions, and analyze the results of the simulation calculations to check whether there are any abnormalities or unexpected situations. Based on the analysis results, optimize the guide vane design to improve the performance and stability of the guide vanes. S6: Make blade samples, install them in wind tunnel test equipment, conduct wind tunnel tests under different conditions, including setting parameters such as wind speed and air pressure, observe and record the response of the blades under different conditions, such as torsion, bending and vibration, analyze according to the experimental data, and optimize the guide blade design to improve the performance and stability of the guide blades; S7: According to the optimized guide blade design, alloy steel or cemented carbide is selected, and the mold structure is designed according to the shape and size of the blade. The mold is heat treated to eliminate internal stress and increase service life. At the same time, the size and shape of the mold are inspected to ensure that its accuracy meets the requirements. Finally, the mold is tested and debugged to ensure its stability and reliability during the processing; S8: Prepare detailed machining procedures according to mold design, and use numerical simulation technology to predict and control cutting force, temperature distribution, etc. during machining; S9: Use high-precision three-dimensional coordinate measuring equipment to conduct a comprehensive inspection of the shape, size and position of the blades, and perform data analysis on the inspection results to ensure that the processing accuracy of the blades meets the requirements.

2. A process for machining guide vanes of a front-end steam compressor of a gas engine as claimed in claim 1, characterized in that: The guide vane is made of any one of a high-temperature alloy and a nickel-based alloy.

3. A process for machining guide vanes of a front-end steam compressor of a gas engine as claimed in claim 1, characterized in that: The three-dimensional modeling software is any one of SolidWorks, UG or CATIA.

4. A process for machining guide vanes of a front-end steam compressor of a gas engine as claimed in claim 1, characterized in that: The numerical simulation software is any one of ANSYS or Fluent.

5. A process for machining guide vanes of a front end steam compressor of a gas engine as claimed in claim 1, characterized in that: The boundary conditions are used to determine the variation of the variables or their derivatives at the boundary of the solution area with time and location.

6. A process for machining guide vanes of a front end steam compressor of a gas engine as claimed in claim 1, characterized in that: The initial conditions are used to study the spatial distribution of various solution variables of the object at the beginning of the process.

7. A process for machining guide vanes of a front-end steam compressor of a gas turbine as claimed in claim 1, characterized in that: The structured grid is used to provide high-quality input for subsequent numerical simulations, so as to understand the flow and heat transfer characteristics of airflow passing through the blades, predict the performance of the guide vanes, and optimize the design.

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