Evaluation method and system for processing blades

Abstract

The present invention relates to the technical field of aero-engine turbine blades, and discloses a method and system for evaluating processed blades. By extracting surface data of processed blades of turbine blades, a maximum dimensional deviation value between the processed blades and a designed blade profile is obtained. Then, by conducting temperature field simulation analysis of the processed blades and the designed blade profile, a ratio between the highest temperature in the temperature field of each processed blade and the average surface temperature of the designed blade profile is obtained, thereby constructing a functional relationship between the ratio and the maximum relative dimensional deviation value of the corresponding processed blade. The functional relationship is used to calculate the ratio calculated value of the processed blade profile to be analyzed, so as to judge whether the processed blade to be analyzed meets the use requirements. The evaluation method of the present invention takes into account the temperature field influence caused by the dimensional deviation during the actual manufacturing of the processed blades, improves the efficiency and accuracy of judging the effectiveness of the processed blades, and ensures that the processed turbine blades meet the design requirements.

Description

Technical Field

[0001] The invention relates to the technical field of aero-engine turbine blades and discloses an evaluation method and system for processing blades. Background Art

[0002] To meet the ever-increasing thrust demands of aircraft engines, the temperature of the gas flowing in front of the turbine of high-performance aircraft engines continues to rise, far exceeding the melting point of the turbine blade material itself. Therefore, effective cooling methods must be employed to reduce the wall temperature of the turbine blades. Currently, typical cooling structures for turbine blades combine external film cooling with enhanced internal cooling channels with turbulent structures. This approach is determined by the advancement of both heat transfer research and processing technology.

[0003] Large machining deviations can occur during turbine blade profile manufacturing, affecting the air film coverage of the blade's leading edge film holes and causing leading edge temperatures to rise. Deviations in cooling pressure and temperature can also lead to temperature increases. Increased mainstream turbulence can lead to a slight decrease in cooling air flow, which in turn increases surface temperatures. Existing gas-thermal coupling analyses of turbine cooling blades fail to account for blade temperature uncertainty caused by manufacturing deviations, making it difficult to quickly assess the effectiveness of machined turbine blades. Summary of the Invention

[0004] The purpose of the present invention is to provide a method and system for evaluating processed blades, which can improve the efficiency and accuracy of judging the effectiveness of processed blades, avoid the randomness, blindness, and error-proneness caused by human experience in screening processed blades, and thus ensure that the processed turbine blades meet the design requirements.

[0005] In order to achieve the above technical effects, the technical solution adopted by the present invention is:

[0006] A method for evaluating a processed blade, comprising:

[0007] Scanning to obtain outer surface profiles of multiple processed blades of the same designed blade profile, generating a three-dimensional model of each processed blade, and analyzing the three-dimensional model of each processed blade to obtain a maximum relative dimensional deviation between the processed blade and the designed blade profile;

[0008] According to the positions of the hollow inner cavity, film holes, and edge plate cooling structure of the designed blade, the corresponding hollow inner cavity, film holes, and edge plate cooling structure are added to each of the three-dimensional models to generate a simulation model of each processed blade;

[0009] Using fluid analysis software, a gas-thermal coupling analysis is performed on the simulation model and the designed blade profile to obtain the temperature fields of the designed blade profile and each processed blade under different assessment working conditions. Based on the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile, a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade is constructed;

[0010] Based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade shape, the ratio calculation value of the blade to be analyzed is obtained by using the functional relationship analysis. If the ratio calculation value is less than or equal to the preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements.

[0011] Furthermore, the preset ratio threshold is based on The analysis obtained is the preset ratio threshold, is the allowable temperature for processing blade materials, It is the average surface temperature of the designed blade under the test conditions.

[0012] Furthermore, fluid simulation software is used to analyze and obtain the cooling air flow value of each simulation model under the design operating conditions, and the relative deviation between the cooling air flow value and the cooling air design value of the designed blade shape is analyzed and obtained. If the relative deviation is greater than the preset deviation threshold, the corresponding processed blade is eliminated, and then the fluid analysis software is used to carry out gas-thermal coupling analysis on the simulation models of the remaining processed blades.

[0013] Furthermore, the preset deviation threshold value ranges from 2% to 3%.

[0014] Furthermore, the method for scanning and obtaining the outer surface profile of the processed blade includes:

[0015] The blade profile curves of the processed blade at different radial height sections are obtained by scanning, and the outer surface blade profile of the processed blade is generated according to the blade profile curves of the processed blade at different radial height sections.

[0016] To achieve the above technical effects, the present invention further provides a blade processing evaluation system for implementing the above blade processing evaluation method, comprising:

[0017] a data acquisition module, configured to scan and obtain the outer surface profiles of a plurality of processed blades of the same designed blade profile, generate a three-dimensional model of each processed blade, and obtain a maximum relative dimensional deviation between the processed blade and the designed blade profile based on analysis of the three-dimensional model of each processed blade;

[0018] A simulation model building module is used to add the corresponding hollow inner cavity, air film hole and edge plate cooling structure to each of the three-dimensional models according to the positions of the hollow inner cavity, air film hole and edge plate cooling structure of the designed blade, so as to generate a simulation model of each processed blade;

[0019] a temperature field analysis module, configured to perform gas-thermal coupling analysis on the simulation model and the designed blade profile using fluid analysis software, obtain the temperature fields of the designed blade profile and each processed blade under different assessment working conditions, and construct a functional relationship between the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile and the maximum relative deviation value of the size of the corresponding processed blade based on the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile;

[0020] An evaluation module is used to obtain a ratio calculation value of the blade profile to be analyzed based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade profile using the functional relationship analysis. If the ratio calculation value is less than or equal to a preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements.

[0021] Furthermore, in the evaluation module, the preset ratio threshold is based on The analysis obtained is the preset ratio threshold, is the allowable temperature for processing blade materials, It is the average surface temperature of the designed blade under the test conditions.

[0022] Furthermore, it also includes a preprocessing module, which is used to use fluid simulation software to analyze and obtain the cooling air flow value of each simulation model under the design working conditions, and analyze and obtain the relative deviation between the cooling air flow value and the cooling air design value of the designed blade type. If the relative deviation is greater than the preset deviation threshold, the corresponding processed blade will be eliminated; the temperature field analysis module uses fluid analysis software to carry out gas-thermal coupling analysis on the simulation models of the remaining processed blades.

[0023] Furthermore, the preset deviation threshold value ranges from 2% to 3%.

[0024] Furthermore, in the data acquisition module, the method for scanning and obtaining the outer surface profile of the processed blade includes:

[0025] The blade profile curves of the processed blade at different radial height sections are obtained by scanning, and the outer surface blade profile of the processed blade is generated according to the blade profile curves of the processed blade at different radial height sections.

[0026] Compared to existing technologies, the present invention offers the following advantages: By constructing a functional relationship between the ratio of the maximum temperature in the temperature field of the processed blade to the average surface temperature of the designed blade profile and the maximum relative dimensional deviation of the corresponding processed blade, the present invention uses this functional relationship to calculate the calculated ratio value for the processed blade profile to determine whether the processed blade meets the requirements. This evaluation method considers the temperature field impact caused by dimensional deviations during actual manufacturing of the processed blade, improving the efficiency and accuracy of determining the effectiveness of the processed blade and avoiding the randomness, blindness, and error-proneness associated with manual experience-based blade screening, thereby ensuring that the processed turbine blade meets the design requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a flow chart of the evaluation method for processing blades in Example 1;

[0028] Figure 2 This is a structural block diagram of the evaluation system for processing blades in Example 1;

[0029] Figure 3 This is a flow chart of the evaluation method for processing blades in Example 2;

[0030] Figure 4 is a quantitative value distribution diagram of the size deviation between a real processed blade and the designed blade profile in Example 2;

[0031] Among them, 1. Data acquisition module; 2. Simulation model construction module; 3. Preprocessing module; 4. Temperature field analysis module; 5. Evaluation module. DETAILED DESCRIPTION

[0032] The present invention will be described in further detail below with reference to the embodiments and accompanying drawings. However, this should not be construed as limiting the scope of the present invention to the following embodiments, as all technologies implemented based on the present invention fall within the scope of the present invention.

[0033] Example 1

[0034] See also Figures 1 to 2 , a method for evaluating a processed blade, comprising:

[0035] Scanning to obtain outer surface profiles of multiple processed blades of the same designed blade profile, generating a three-dimensional model of each processed blade, and analyzing the three-dimensional model of each processed blade to obtain a maximum relative dimensional deviation between the processed blade and the designed blade profile;

[0036] According to the positions of the hollow inner cavity, film holes, and edge plate cooling structure of the designed blade, the corresponding hollow inner cavity, film holes, and edge plate cooling structure are added to each of the three-dimensional models to generate a simulation model of each processed blade;

[0037] Using fluid analysis software, a gas-thermal coupling analysis is performed on the simulation model and the designed blade profile to obtain the temperature fields of the designed blade profile and each processed blade under different assessment working conditions. Based on the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile, a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade is constructed;

[0038] Based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade shape, the ratio calculation value of the blade to be analyzed is obtained by using the functional relationship analysis. If the ratio calculation value is less than or equal to the preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements.

[0039] In this embodiment, by extracting surface data from the processed turbine blades, the maximum dimensional deviation between the processed blades and the designed blade profile is obtained. Then, by conducting a temperature field simulation analysis of the processed blades and the designed blade profile, the ratio between the highest temperature in the temperature field of each processed blade and the average surface temperature of the designed blade profile is obtained. A functional relationship is constructed between this ratio and the maximum relative dimensional deviation of the corresponding processed blade. This functional relationship is used to calculate the calculated ratio value for the processed blade profile to be analyzed, thereby determining whether the processed blade to be analyzed meets the requirements for use. The evaluation method for processed blades in this embodiment considers the temperature field impact caused by dimensional deviations during actual manufacturing of the processed blades, improves the efficiency and accuracy of determining the effectiveness of the processed blades, and avoids the randomness, blindness, and error-proneness associated with manual experience-based screening of processed blades, thereby ensuring that the processed turbine blades meet the design requirements.

[0040] Based on the same inventive concept, a blade processing evaluation system is also provided, which is used to implement the blade processing evaluation method, including:

[0041] Data acquisition module 1 is used to scan and obtain the outer surface profiles of multiple processed blades of the same designed blade profile, and generate a three-dimensional model of each processed blade, and obtain the maximum relative dimensional deviation between the processed blade and the designed blade profile based on the three-dimensional model of each processed blade;

[0042] Simulation model construction module 2 is used to add the corresponding hollow inner cavity, air film hole and edge plate cooling structure to each of the three-dimensional models according to the position of the hollow inner cavity, air film hole and edge plate cooling structure of the designed blade, so as to generate a simulation model of each processed blade;

[0043] a temperature field analysis module 4 for performing gas-thermal coupling analysis on the simulation model and the designed blade profile using fluid analysis software to obtain the temperature fields of the designed blade profile and each processed blade under different assessment working conditions, and constructing a functional relationship between the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile and the maximum relative deviation value of the size of the corresponding processed blade based on the ratio of the highest temperature in the temperature field of each processed blade to the average surface temperature of the designed blade profile;

[0044] Evaluation module 5 is used to obtain a ratio calculation value of the blade to be analyzed based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade profile using the functional relationship analysis. If the ratio calculation value is less than or equal to the preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements.

[0045] The evaluation system for processed blades in this embodiment also includes a preprocessing module 3, which is used to use fluid simulation software to analyze and obtain the cooling air flow value of each simulation model under the design operating conditions, and analyze and obtain the relative deviation between the cooling air flow value and the cooling air design value of the designed blade shape. If the relative deviation is greater than the preset deviation threshold, the corresponding processed blade is eliminated; the temperature field analysis module 4 uses fluid analysis software to perform gas-thermal coupling analysis on the simulation models of the remaining processed blades.

[0046] Example 2

[0047] See also Figure 3 and Figure 4 This embodiment takes the effectiveness evaluation of a blade processed by a turbine blade of a certain design as an example to describe the evaluation method of the blade processed by the present invention in detail. The specific evaluation steps are as follows:

[0048] Step 1: Scan and obtain the outer surface profiles of multiple processed blades of the same designed blade profile, and generate a three-dimensional model of each processed blade; and analyze the three-dimensional model of each processed blade to obtain the maximum relative dimensional deviation between the processed blade and the designed blade profile;

[0049] In this embodiment, a three-dimensional coordinate measuring machine is used to scan and obtain the blade profile curves of the processed blade at different radial height sections. In the blade profile curve recovery, a curve fitting tool is used to perform smoothing processing on the points near the film holes to supplement the missing data and form the measurement point data of the entire section.

[0050] According to the blade profile curves of different radial height sections, blade profile data of multiple sections are obtained through inverse design in combination with a blade aerodynamic shaping program to generate the outer surface blade profile of the processed blade.

[0051] like Figure 4A distribution diagram of the dimensional deviation between a real, machined blade and the designed blade profile is presented, with the horizontal axis representing the relative arc length (0.00 represents the leading edge stagnation point, negative numbers represent the relative arc lengths of the nodes at the blade basin, and positive numbers represent the relative arc lengths of the nodes at the blade back). It can be seen that the maximum deviation in the leading edge area near the blade back can reach 0.53mm, while the leading edge near the blade basin is relatively good. The manufacturing deviation in the blade mid-chord area is approximately 0.1mm-0.35mm, and the machining deviation in the trailing edge area is relatively low.

[0052] Step 2: According to the positions of the hollow inner cavity, air film holes, and edge plate cooling structure of the designed blade, the corresponding hollow inner cavity, air film holes, and edge plate cooling structure are added to each of the three-dimensional models to generate a simulation model of each processed blade;

[0053] Step 3: Using fluid simulation software to analyze and obtain the cooling air flow value of each simulation model under the design working conditions, and analyzing and obtaining the relative deviation between the cooling air flow value and the cooling air design value of the designed blade profile; if the relative deviation is greater than a preset deviation threshold, the corresponding processed blade is eliminated;

[0054] The preset deviation threshold is in the range of 2%-3%. In this embodiment, the preset deviation threshold is 2.6%. If the relative deviation is greater than the preset deviation threshold of 2.6%, the corresponding processed blade will be eliminated.

[0055] Step 4: Using fluid analysis software, perform gas-thermal coupling analysis on the simulation model and the designed blade profile, respectively, to obtain the temperature fields of the designed blade profile and each processed blade under different assessment working conditions; based on the ratio between the highest temperature in the temperature field of each processed blade and the average surface temperature of the designed blade profile, construct a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade;

[0056] In this example, ANSYS CFX software was used to perform coupled gas-thermal analysis. A variable specific heat gas was used in the fluid domain, and the SST model with a transition model was used as the turbulence model. A FluidSolid interface was established between the solid and fluid domains. An unstructured grid was used for the computational grid, and CFX was used to calculate the temperature field to obtain the temperature field of the machined blade.

[0057] In this embodiment, based on the ratio between the maximum temperature in the temperature field of each processed blade and the average temperature of the designed blade surface, a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade is constructed as follows: ,in is the ratio between the maximum temperature in the temperature field of the processed blade and the average temperature of the designed blade surface, It is the maximum relative deviation of the size of the processed blade.

[0058] Step 5. Based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade shape, the ratio calculation value of the blade to be analyzed is obtained by using the functional relationship analysis. If the ratio calculation value is less than or equal to the preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements.

[0059] In this embodiment, the preset ratio threshold is based on The analysis obtained is the preset ratio threshold, is the allowable temperature for processing blade materials, is the average surface temperature of the designed blade under the test conditions. and For comparison, when > When the blade to be analyzed does not meet the requirements, the blade is unusable; when ≤ When, the leaves are available.

[0060] Before constructing the functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade, this embodiment pre-eliminates the processed blades whose cooling air flow does not meet the requirements. This can exclude the processed blades whose cooling air flow obviously deviates from the design requirements, ensure the accuracy and reliability of subsequent analysis, effectively improve the analysis accuracy of the functional relationship, ensure the accuracy and practicality of the final evaluation results, and provide strong support for the quality control and optimization of the processed blades.

[0061] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for evaluating a processed blade, characterized in that: include: Scanning to obtain outer surface profiles of multiple processed blades of the same designed blade profile, generating a three-dimensional model of each processed blade, and analyzing the three-dimensional model of each processed blade to obtain a maximum relative dimensional deviation between the processed blade and the designed blade profile; According to the positions of the hollow inner cavity, film holes, and edge plate cooling structure of the designed blade, the corresponding hollow inner cavity, film holes, and edge plate cooling structure are added to each of the three-dimensional models to generate a simulation model of each processed blade; The simulation model and the designed blade are analyzed by gas-heat coupling using fluid analysis software to obtain the temperature field of the designed blade and each processed blade under different test conditions. According to the ratio between the highest temperature in the temperature field of each processed blade and the average surface temperature of the designed blade, a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade is constructed. ,in is the ratio between the maximum temperature in the temperature field of the processed blade and the average temperature of the designed blade surface, is the maximum relative deviation of the size of the processed blade; According to the maximum relative deviation value of the size of the blade to be analyzed of the designed blade shape, the ratio calculation value of the blade shape to be analyzed is obtained by using the functional relationship analysis. If the ratio calculation value is less than or equal to the preset ratio threshold, the corresponding blade to be analyzed meets the use requirements, otherwise the processed blade does not meet the requirements; the preset ratio threshold is based on The analysis obtained is the preset ratio threshold, is the allowable temperature for processing blade materials, It is the average surface temperature of the designed blade under the test conditions.

2. The method for evaluating a processed blade according to claim 1, wherein: Fluid simulation software is used to analyze and obtain the cooling air flow value of each simulation model under the design operating conditions, and the relative deviation between the cooling air flow value and the cooling air design value of the designed blade profile is analyzed and obtained. If the relative deviation is greater than the preset deviation threshold, the corresponding processed blade is eliminated, and then the fluid analysis software is used to perform gas-thermal coupling analysis on the simulation models of the remaining processed blades.

3. The method for evaluating a processed blade according to claim 2, wherein: The preset deviation threshold value ranges from 2% to 3%.

4. The method for evaluating a processed blade according to any one of claims 1 to 3, characterized in that: Methods for scanning and obtaining the outer surface profile of a machined blade include: The blade profile curves of the processed blade at different radial height sections are obtained by scanning, and the outer surface blade profile of the processed blade is generated according to the blade profile curves of the processed blade at different radial height sections.

5. A processing blade evaluation system for implementing the processing blade evaluation method according to claim 1, characterized in that: include: a data acquisition module, configured to scan and obtain the outer surface profiles of a plurality of processed blades of the same designed blade profile, generate a three-dimensional model of each processed blade, and obtain a maximum relative dimensional deviation between the processed blade and the designed blade profile based on analysis of the three-dimensional model of each processed blade; A simulation model building module is used to add the corresponding hollow inner cavity, air film hole and edge plate cooling structure to each of the three-dimensional models according to the positions of the hollow inner cavity, air film hole and edge plate cooling structure of the designed blade, so as to generate a simulation model of each processed blade; The temperature field analysis module is used to perform gas-thermal coupling analysis on the simulation model and the designed blade profile using fluid analysis software to obtain the temperature field of the designed blade profile and each processed blade under different assessment working conditions. According to the ratio between the highest temperature in the temperature field of each processed blade and the average surface temperature of the designed blade profile, a functional relationship between the ratio and the maximum relative deviation value of the size of the corresponding processed blade is constructed. ,in is the ratio between the maximum temperature in the temperature field of the processed blade and the average temperature of the designed blade surface, is the maximum relative deviation of the size of the processed blade; The evaluation module is used to obtain a ratio calculation value of the blade to be analyzed based on the maximum relative deviation value of the size of the blade to be analyzed of the designed blade profile by using the functional relationship analysis. If the ratio calculation value is less than or equal to a preset ratio threshold, the corresponding blade to be analyzed meets the use requirements; otherwise, the processed blade does not meet the requirements; the preset ratio threshold is based on The analysis obtained is the preset ratio threshold, is the allowable temperature for processing blade materials, It is the average surface temperature of the designed blade under the test conditions.

6. The evaluation system for processing blades according to claim 5, characterized in that: The system further includes a pre-processing module for analyzing and obtaining a cooling air flow value of each simulation model under the design working condition using fluid simulation software, and analyzing and obtaining a relative deviation between the cooling air flow value and the cooling air design value of the designed blade profile, and if the relative deviation is greater than a preset deviation threshold, removing the corresponding processed blade; The temperature field analysis module uses fluid analysis software to perform gas-thermal coupling analysis on the simulation model of the remaining processed blades.

7. The processing blade evaluation system according to claim 6, characterized in that: The preset deviation threshold value ranges from 2% to 3%.

8. The processing blade evaluation system according to any one of claims 5 to 7, characterized in that: In the data acquisition module, the method for scanning and obtaining the outer surface profile of the processed blade includes: The blade profile curves of the processed blade at different radial height sections are obtained by scanning, and the outer surface blade profile of the processed blade is generated according to the blade profile curves of the processed blade at different radial height sections.

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