Double-wall blade design method based on process parameters, medium and computer system

Abstract

The invention discloses a double-wall blade design method based on process parameters, a medium and a computer system. The method comprises the following steps: determining structural parameters and process parameters of the double-layer wall blade based on dimensional tolerance constraint and process limitation constraint of the double-layer wall blade; executing precision casting numerical simulation based on the structure parameters and the process parameters to generate a precision casting model; generating a structural parameter-process parameter deformation data set of the blade based on the precision casting model; determining a mapping relation between the structure parameter-process parameter deformation data set and the deformation of the double-wall blade; determining whether the blade model based on the process parameters can be manufactured or not based on the mapping relation and in combination with the structure parameters; outputting the blade model based on the process parameters for further analysis under the condition of determining that the blade model based on the process parameters can be manufactured; and outputting a design model of the double-wall blade under the condition that the design requirements are met through further analysis.

Description

Technical Field

[0001] This application relates to the technical field of turbine blades of an engine, specifically to double-wall blades of turbine blades, and more specifically, to a design method, medium, and computer system of double-wall blades based on process parameters. Background Art

[0002] As one of the core key components of an aeroengine, the hollow turbine blade has high requirements for its aerodynamic structure and dimensional accuracy, complex manufacturing processes, and the manufacturing workload accounts for about 33% of the entire engine, and is known as "the pearl on the crown of manufacturing".

[0003] Currently, the design temperature at the inlet before the turbine of the next-generation aeroengine is nearly 2000 degrees Celsius. To cope with the continuously rising turbine inlet temperature and ensure that the turbine blade can serve reliably for a long time under the working conditions of strong thermal shock and complex cyclic thermal stress, the traditional composite-cooled hollow blade is gradually evolving towards a highly efficient cooled blade with a double-wall cooling structure. The double-wall structure can increase the temperature-bearing capacity of the existing complex single-crystal superalloy hollow blade by about 300°C and has the ability to improve the cooling efficiency by 20%-30%, and has become the next-generation turbine blade cooling structure that is focused on at home and abroad.

[0004] Currently, the hollow turbine blade generally adopts single-crystal net-shape precision casting. However, the existing double-wall structure uses traditional manufacturing means driven by empirical trial and error, so it has the following disadvantages:

[0005] Lack of relevant basic data for forming and processing; do not consider the influence law of process parameters on accuracy; lack of understanding of the deformation evolution mechanism of forming and processing; no systematic summary of process control methods for forming accuracy control, etc.

[0006] Therefore, in the design process of double-wall blades, the precision casting process of the blades has never been effectively simulated, the process feasibility has not been considered, and the influence of the deviation of the blades during the forming process on the blade cooling, aerodynamic performance, strength, and life has not been considered, resulting in the possibility that the performance indicators of the cast and processed blades may not meet the expectations, thus causing serious consequences threatening the safe operation of the engine.

[0007] Therefore, there is an urgent need in this field for a new type of double-wall blade design method that can comprehensively consider the influence of process parameters and structural design parameters on the precision casting process and perform machining and manufacturing based on accurate simulation, thereby ensuring the high quality of the formed blades. Summary of the Invention

[0008] A brief overview of one or more aspects is given below to provide a basic understanding of these aspects. This overview is not an exhaustive survey of all contemplated aspects and is neither intended to identify key or decisive elements of all aspects nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that follows.

[0009] According to a first aspect of the present application, a method for designing a double-walled blade based on process parameters is provided. The method includes the following steps: Step S1: Determine the structural parameters and process parameters of the double-walled blade based on the dimensional tolerance constraints and process limit constraints of the double-walled blade; Step S2: Perform precision casting numerical simulation based on the structural parameters and the process parameters to generate a precision casting model; Step S3: Generate a structural parameter-process parameter deformation data set of the blade based on the precision casting model; Step S4: Determine the mapping relationship between the structural parameter-process parameter deformation data set and the deformation of the double-walled blade; Step S5: Determine whether the blade model based on process parameters is manufacturable based on the mapping relationship and in combination with the structural parameters; Step S6: When it is determined that the blade model based on process parameters is manufacturable, output the blade model based on process parameters for further analysis; and Step S7: When all the further analyses meet the design requirements, output the design model of the double-walled blade.

[0010] According to a preferred embodiment of the present application, performing precision casting numerical simulation based on the structural parameters and the process parameters to generate a precision casting model includes: performing one or more sets of precision casting numerical simulations; performing a precision casting test to verify the precision casting numerical simulation results; and performing more sets of precision casting numerical simulations to generate the precision casting model.

[0011] According to a preferred embodiment of the present application, determining the mapping relationship between the structural parameter-process parameter deformation data set and the deformation of the double-walled blade includes: applying the Back Propagation (BP) neural network algorithm to determine the mapping relationship.

[0012] According to a preferred embodiment of the present application, performing other parameter analyses on the blade model based on process parameters to output the design model of the double-walled blade includes: performing fluid-solid-thermal coupling numerical analysis of the blade on the blade model based on process parameters to determine whether the blade model based on process parameters meets the aerodynamic and temperature field design requirements; and determining whether the blade model based on process parameters meets the strength and life design requirements.

[0013] According to a preferred embodiment of the present application, if the blade model based on process parameters does not meet the aerodynamic or temperature field design requirements, then return to modify the structural parameters of the double-walled blade and determine again whether the blade model based on process parameters is manufacturable.

[0014] According to a preferred embodiment of the present application, if it is determined that the blade model based on process parameters does not meet the strength or life design requirements, then return to modify the structural parameters of the double-wall blade and determine again whether the blade model based on process parameters is manufacturable.

[0015] According to a preferred embodiment of the present application, determining whether the blade model based on process parameters meets the aerodynamic and temperature field design requirements is achieved by performing a fluid-structure-thermal coupling numerical analysis on the blade model based on process parameters.

[0016] According to a preferred embodiment of the present application, if it is determined that the blade model based on process parameters is not manufacturable, then return to modify the structural parameters of the double-wall blade and determine again whether the blade model based on process parameters is manufacturable.

[0017] According to a second aspect of the present application, there is provided a computer medium having instructions stored thereon, which when executed by a computer, implement the steps of the method as described above.

[0018] According to a third aspect of the present application, there is provided another computer system, which includes: a processor; a memory having a computer-readable program stored thereon, wherein when the computer-readable program is executed by the processor, the steps of the method as described above are executed.

[0019] To achieve the foregoing and related purposes, one or more of these aspects include the features that are fully described hereinafter and particularly pointed out in the appended claims. The following description and the drawings set forth in detail certain illustrative features of one or more of these aspects. However, these features are merely indicative of some of the various ways in which the principles of the various aspects may be employed, and this description is intended to cover all such aspects and their equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to understand in detail the manner in which the features described above of the present application are used, the above briefly summarized content may be described in more detail with reference to the various aspects, some of which are illustrated in the drawings. It should be noted, however, that the drawings only illustrate certain typical aspects of the present application and should not be considered to limit its scope, since the description may admit of other equally effective aspects.

[0021] In the drawings:

[0022] Figure 1 is a top view of the structure of the double-wall blade described herein;

[0023] Figure 2 is a specific flowchart of the double-wall blade design method based on process parameters according to a preferred embodiment of the present application; and

[0024] Figure 3 It is a structural block diagram of a computer system for explaining aspects of implementing the design method described herein. Detailed implementation

[0025] The following detailed description presented in conjunction with the accompanying drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein can be practiced. The detailed description includes specific details to provide a thorough understanding of the various concepts. However, it will be apparent to those skilled in the art that these concepts can be practiced without these specific details. In some instances, well-known components are shown in block diagram form to avoid obscuring such concepts.

[0026] It should be understood that based on this disclosure, other embodiments will be apparent and system, structural, process, or mechanical changes can be made without departing from the scope of this disclosure.

[0027] As described above, in the existing double-walled blade design process, since neither the process feasibility nor the influence of investment casting process parameters on blade cooling, aerodynamic performance, strength, and life is considered, the blades processed through this design process may not meet the actual performance requirements, thus endangering the safe operation of the engine.

[0028] This application aims to obtain a double-walled blade structure parameter / investment casting process data set through numerical simulation of the investment casting process; then, through a neural network method, establish a mapping relationship between the blade structure parameters / investment casting process parameters and blade deformation, and further evaluate the manufacturability of the designed double-walled blade. After obtaining a double-walled blade model considering investment casting process parameters, a fluid-structure-thermal coupling analysis of the double-walled blade based on process parameters is carried out, and then the aerodynamic performance, cooling efficiency, strength, and life of the blade are evaluated, so as to finally obtain a double-walled blade design model based on process parameters, structural parameters and with various performances meeting the actual requirements. This not only improves the design iteration efficiency of the blade and shortens the blade design iteration cycle; but also, since the influence of dimensional deviations caused by the investment casting process on blade aerodynamics, heat transfer, strength, and life is taken into account, the analysis and evaluation results are more accurate, thereby improving the reliability of the double-walled blade design and ensuring the safe operation of the aeroengine.

[0029] The following describes the implementation process of this application in detail in conjunction with the accompanying drawings.

[0030] Figure 1 Illustrated is a structural top view of a double-walled blade according to the description herein.

[0031] As Figure 1As shown, the double-walled blade includes an outer wall 1, an inner wall 2, and a gap therebetween. This double-walled structure has higher high-temperature resistance and better cooling effect compared to traditional composite cooling hollow blades. Therefore, the double-walled blade has become the next-generation turbine blade cooling structure that is focused on layout at home and abroad and has an extremely wide range of applications.

[0032] Referring Figures 2-3 , aspects are depicted with reference to one or more components and one or more methods that can perform the actions or functions described herein. In one aspect, the term "component" as used herein can be one of the parts that make up a system, can be hardware or software or some combination thereof, and can be divided into other components. Although the operations described below in Figure 2 are presented in a specific order and / or as performed by example components, it should be understood that the order of these actions and the components performing the actions can vary depending on the implementation. In addition, it should be understood that the following actions or functions can be performed by a specially programmed processor, a processor executing specially programmed software or a computer-readable medium, or any other combination of hardware components and / or software components capable of performing the described actions or functions.

[0033] Figure 2 The specific flowchart of the double-walled blade design method based on process parameters according to the preferred embodiment of the present application is shown in

[0034] As Figure 2 shown, the design method mainly includes the following steps.

[0035] First, at step S1, based on the basic blade shape of the double-walled blade to be designed and the existing process conditions, the key structural parameters and precision casting process parameters of the blade are determined.

[0036] Specifically, based on the dimensional tolerance constraints and process limit constraints of the double-walled blade, the structural parameters and process parameters of the double-walled blade are determined.

[0037] Next, at step S2, based on the determined structural parameters and process parameters, a numerical simulation of the precision casting process is performed to generate a precision casting model.

[0038] This step is mainly achieved through the following operations.

[0039] First, perform one or more sets of numerical simulations of the precision casting process, and then perform a precision casting test to verify whether the precision casting numerical simulation results meet the design requirements. If they meet, continue to perform a large number of precision casting numerical simulations, so as to be able to generate the corresponding precision casting model.

[0040] Next, proceed to step S3. Here, based on the generated investment casting model, a dataset of the structural parameters - process parameters and blade deformation of the double-walled blade is generated.

[0041] Then, at step S4, by applying the BP (Back Propagation) neural network algorithm, a mapping relationship between the structural parameters, investment casting process parameters, and blade deformation is established.

[0042] As is known to those skilled in the art, the BP network is a multi-layer feedforward network trained by the error backpropagation algorithm and is one of the most widely used neural network models currently. The BP network can learn and store a large number of input-output pattern mapping relationships without prior disclosure of the mathematical equations describing such mapping relationships. Therefore, the BP algorithm is suitable for establishing the mapping relationship between input and output.

[0043] Although the use of the BP algorithm to establish the mapping relationship between the structural parameters, process parameters, and blade deformation is described in this article, the present application is not limited to this algorithm. Current and future possible mapping algorithms are included within the scope of the present application, and the application of different mapping algorithms does not affect the implementation of the main solution of the present application.

[0044] Now proceed to step S5. Based on this mapping relationship and combined with the structural parameters, determine whether the blade model based on the process parameters is manufacturable.

[0045] Specifically, comprehensively consider the structural parameter design of the blade and combine the above mapping relationship to judge the manufacturability of the designed blade under certain process conditions.

[0046] If it is determined that the blade can be manufactured and meets the corresponding conditions, proceed to step S6, and output the blade model considering the investment casting process parameters for further analysis.

[0047] On the contrary, if the dimensional tolerance requirements cannot be met or the structural dimensions exceed the process limit conditions, return to modify the structural design of the blade and judge the manufacturability of the blade again.

[0048] Among them, in step S6, the following parameter analysis is mainly carried out on the output blade model considering the investment casting process parameters.

[0049] At step S601, evaluate whether the aerodynamic performance and temperature field of the blade meet the design requirements. This evaluation is mainly carried out through the commonly used fluid-structure-thermal coupling analysis in this field. Such coupling analysis is a common means in this field, so it will not be elaborated here to avoid affecting the description of the main technical solution of the present application.

[0050] Then, at step S602, evaluate whether the strength and life of the blade meet the design requirements.

[0051] When the above evaluation results all indicate that the indexes such as the blade aerodynamic performance, temperature field, strength, and life meet the design requirements, the design model of the double-wall blade is output at step S7, and the design iteration is ended.

[0052] Of course, if the blade model based on the process parameters does not meet the aerodynamic or temperature field design requirements, return to modify the structural parameters of the double-wall blade and determine again whether the blade model based on the process parameters is manufacturable.

[0053] Similarly, if it is evaluated that the blade model based on the process parameters does not meet the strength or life design requirements, return to modify the structural parameters of the double-wall blade and determine again whether the blade model based on the process parameters is manufacturable.

[0054] This application also discloses a computer medium storing instructions, which can implement the steps of the method as described above when the instructions are executed by a computer.

[0055] Figure 3 A structural block diagram of a computer system for implementing aspects of the design method described herein is also shown.

[0056] As Figure 3 shown, the computer system includes a processor 10 and a memory 20. A computer-readable program 30 is stored on the memory 20, and when the computer-readable program 30 is executed by the processor 10, it can execute the steps of the method as described above in this application.

[0057] Aspects, elements, or any portion of an element, or any combination of elements according to the present disclosure may be implemented using a "processing system" that includes one or more processors. Examples of processors include: microprocessors, microcontrollers, digital signal processors (DSPs), field programmable gate arrays (FPGAs), programmable logic devices (PLDs), state machines, gated logic, discrete hardware circuits, and other suitable hardware configured to perform the various functions described throughout the present disclosure. One or more processors in the processing system may execute software. Software should be broadly construed to mean instructions, instruction sets, code, code segments, program code, programs, subprograms, software modules, applications, software applications, software packages, routines, subroutines, objects, executables, threads of execution, procedures, functions, etc., regardless of whether it is referred to in terms of software, firmware, middleware, microcode, hardware description language, or other terms. The software may reside on a computer-readable medium. The computer-readable medium may be a non-transitory computer-readable medium. By way of example, non-transitory computer-readable media include: magnetic storage devices (e.g., hard disks, floppy disks, magnetic strips), optical disks (e.g., compact disks (CDs), digital versatile disks (DVDs)), smart cards, flash memory devices (e.g., memory cards, memory sticks, key drives), random access memory (RAM), read only memory (ROM), programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), registers, removable disks, and any other suitable medium for storing software and / or instructions that can be accessed and read by a computer. By way of example, computer-readable media may also include carrier waves, transmission lines, and any other suitable medium for conveying software and / or instructions that can be accessed and read by a computer. The computer-readable medium may reside within the processing system, outside the processing system, or be distributed across multiple entities including the processing system. The computer-readable medium may be embodied in a computer program product. By way of example, the computer program product may include the computer-readable medium in a package material. Those skilled in the art will recognize how best to implement the described functionality presented throughout the present disclosure depending on the particular application and overall design constraints imposed on the overall system.

[0058] It should be understood that the specific order or hierarchy of steps in the disclosed methods is illustrative of exemplary processes. Based on design preferences, it should be understood that the specific order or hierarchy of steps in the methods or methodologies described herein may be rearranged. The appended method claims present the elements of the various steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented, unless specifically recited herein.

[0059] The foregoing description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein, but are to be accorded the full scope consistent with the claim language, wherein the recitation of a singular element is not intended to mean "one and only one" (unless specifically so stated) but "one or more". Unless specifically stated otherwise, the term "some" means one or more. A phrase reciting "at least one" of a list of items refers to any combination of those items, including a single member. As an example, "at least one of a, b, or c" is intended to cover: at least one a; at least one b; at least one c; at least one a and at least one b; at least one a and at least one c; at least one b and at least one c; and at least one a, at least one b, and at least one c. Elements of the various aspects described throughout this disclosure are expressly incorporated herein by reference and are intended to be covered by the claims, all structural and functional equivalents thereof known to those of ordinary skill in the art now or hereafter. Moreover, nothing disclosed herein is intended to be dedicated to the public, whether or not such disclosure is explicitly recited in the claims.

Claims

1. A double-wall blade design method based on process parameters, characterized in that: The method comprises the following steps: Step S1: determining the structural parameters and process parameters of the double-wall blade based on the dimensional tolerance constraint and process limitation constraint of the double-wall blade; Step S2: performing precision casting numerical simulation based on the structural parameters and the process parameters to generate a precision casting model; Step S3: generating a structural parameter-process parameter deformation data set of the blade based on the precision casting model; Step S4: determining a mapping relationship between the structural parameter-process parameter deformation data set and the deformation of the double-wall blade; Step S5: determining whether the blade model based on the process parameters is manufacturable based on the mapping relationship and in combination with the structural parameters; Step S6: if it is determined that the blade model based on the process parameters is manufacturable, outputting the blade model based on the process parameters for further analysis; and Step S7: When the further analysis meets the design requirements, the design model of the double-wall blade is output.

2. The design method according to claim 1, characterized in that: Performing precision casting numerical simulation based on the structural parameters and the process parameters to generate a precision casting model comprises: Perform one or more sets of investment casting numerical simulations; Perform investment casting tests to verify the investment casting numerical simulation results; and More sets of investment casting numerical simulations are performed to generate the investment casting model.

3. The design method according to claim 1, characterized in that: Determining the mapping relationship between the structural parameter-process parameter deformation data set and the deformation of the double-wall blade includes: The Back Propagation BP neural network algorithm is applied to determine the mapping relationship.

4. The design method according to claim 1, characterized in that: In the case where it is determined that the blade model based on the process parameters is manufacturable, outputting the blade model based on the process parameters for further analysis comprises: Step S601: determining whether the blade model based on the process parameters meets the aerodynamic and temperature field design requirements; and Step S602: Determine whether the blade model based on the process parameters meets the strength and life design requirements.

5. The design method according to claim 5, characterized in that: If the blade model based on the process parameters does not meet the aerodynamic or temperature field design requirements, the method returns to modify the structural parameters of the double-wall blade and determines again whether the blade model based on the process parameters is manufacturable.

6. The design method according to claim 5, characterized in that: If it is determined that the blade model based on the process parameters does not meet the strength or life design requirements, the method returns to modify the structural parameters of the double-wall blade and determines again whether the blade model based on the process parameters is manufacturable.

7. The design method according to claim 5, characterized in that: Determining whether the blade model based on the process parameters meets the aerodynamic and temperature field design requirements is achieved by performing blade flow, solid and thermal coupling numerical analysis on the blade model based on the process parameters.

8. The design method according to claim 1, characterized in that: If it is determined that the blade model based on the process parameters is not manufacturable, the method returns to modify the structural parameters of the double-wall blade and determines again whether the blade model based on the process parameters is manufacturable.

9. A computer-readable medium having instructions stored thereon, which, when executed by a computer, implements the steps of the method according to any one of claims 1 to 8.

10. A computer system comprising: processor; a memory having a computer readable program stored thereon, When the computer-readable program is executed by the processor, the steps of the method according to any one of claims 1 to 8 are performed.

Images