Multi-level prediction method for fatigue life of additive manufacturing component of rocket engine
By performing multiple sampling and model establishment on the additive manufacturing components of rocket engines, combined with simulation simulation and fatigue testing, the problem of large life dispersion in the existing technology is solved, accurate fatigue life prediction is achieved, and the accuracy and reliability of prediction are improved.
Patent Information
- Application Number
- CN202510423569.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-07
- Publication Date
- 2025-08-12
AI Technical Summary
The prior art is difficult to accurately predict the fatigue life of additive manufacturing components of reusable liquid rocket engines, and there are internal defects and surface quality problems, resulting in large life dispersion and lack of effective strength theories and methods to support the engineering of additive manufacturing technology.
By performing multiple sampling on additive manufacturing components, processing standard test parts, and conducting simulation and testing, a multi-level model is established, including the first model, the second model and the third model, combined with finite element analysis and fatigue testing, the model is gradually optimized and verified, and accurate prediction of component life is achieved.
Accurate prediction of the fatigue life of rocket engine additive manufacturing components is achieved, the accuracy and reliability of life prediction is improved, and the prediction problem caused by structural performance dispersion is solved.
Smart Images
Figure CN120470828A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the technical field of reusable liquid rocket engines, and in particular to a multi-level prediction method for fatigue life of rocket engine additively manufactured components. Background Art
[0002] The increasing demand for reusable rockets is placing new and higher demands on the lifespan of additively manufactured components under complex loads. However, due to issues such as internal defects, surface quality, and the influence of molding direction, fatigue life in additively manufactured components has a large dispersion, strength-life verification faces technical bottlenecks, and there is a lack of advanced strength theories and methods to support the engineering of additive manufacturing technology. Therefore, research on fatigue life methods for additively manufactured components in reusable liquid rocket engines is particularly important.
[0003] Additive manufacturing components are characterized by three-dimensional, integrated molding, resulting in structures that are non-uniform, anisotropic, and dependent on the scanning path and process at each point. This makes material-level mechanical testing potentially incapable of predicting the mechanical properties of the structure. Therefore, it is necessary to develop mechanical testing at different levels, from the material level to structural simulations. This requires the use of a comprehensive prediction approach encompassing theoretical research, numerical simulation, and optimized design, and the establishment of validation and optimization strategies based on test results at different levels.
[0004] It should be noted that the information disclosed in the above background technology section is only used to enhance the understanding of the background of the present disclosure, and therefore may include information that does not constitute prior art known to ordinary technicians in the field. Summary of the Invention
[0005] The present invention aims to overcome the shortcomings of the above-mentioned prior art and provide a multi-level fatigue life prediction method for additively manufactured rocket engine components, so as to accurately measure the mechanical properties of additively manufactured components and accurately predict the service life of additively manufactured components.
[0006] According to one aspect of the present disclosure, a multi-level prediction method for fatigue life of rocket engine additively manufactured components is provided, comprising:
[0007] Take multiple samples on the additively manufactured component and process standard test pieces based on the samples;
[0008] Performing simulation on the standard test piece to establish a first model;
[0009] Building a second model based on the first model, and manufacturing a simulation part based on the second model;
[0010] Testing the simulation component to form a third model, and verifying and optimizing the first model based on the third model;
[0011] Fatigue testing is performed on the additively manufactured components of the rocket engine, the life of the additively manufactured components of the rocket engine is predicted based on the third model, and the simulation part is guided according to the fatigue test.
[0012] According to one embodiment of the present disclosure, multiple sampling is performed on the additively manufactured component, and before a standard test piece is processed based on the sampling, the actual load of the additively manufactured component is determined according to a force transmission device, and multiple sampling is performed along the actual load direction.
[0013] According to one embodiment of the present disclosure, when simulating the standard test piece and establishing the first model, the expansion coefficient, quasi-static stretching, high and low cycle fatigue of the standard test piece at different temperatures are tested to obtain relevant parameters, and a finite element model is established based on the relevant parameters.
[0014] According to one embodiment of the present disclosure, when simulating the standard test piece to establish the first model, the standard test piece is tested to obtain corresponding mechanical performance parameters and fatigue performance indicators to establish the first model.
[0015] According to one embodiment of the present disclosure, when establishing a second model based on the first model and manufacturing a simulation part based on the second model, an additive manufacturing component simulation model is first established based on the first model, the simulation model is tested to obtain the second model, and the simulation part is designed and manufactured based on the second model.
[0016] According to one embodiment of the present disclosure, when the simulation part is tested to form a third model, and the first model is verified and optimized based on the third model, a fatigue performance test is performed on the simulation part to form the third model.
[0017] According to one embodiment of the present disclosure, the simulation part is tested to form a third model, and when the first model is verified and optimized based on the third model, the relevant parameters of the first model are verified based on the third model, and the selection of the standard test part material is guided by the third model.
[0018] According to one embodiment of the present disclosure, when fatigue testing is performed on a rocket engine additively manufactured component, the life of the rocket engine additively manufactured component is predicted based on the third model, and the simulation part is verified and optimized according to the fatigue test, the life of the additively manufactured component is measured to be between 175,000 and 176,000 times.
[0019] According to one embodiment of the present disclosure, when fatigue testing is performed on an additively manufactured component of a rocket engine, the life of the additively manufactured component of the rocket engine is predicted based on the third model, and the simulation part is guided according to the fatigue test, the prediction of the life of the additively manufactured component by the third model formed by the simulation part is verified based on the results of the fatigue test of the additively manufactured component.
[0020] According to one embodiment of the present disclosure, when fatigue testing is performed on a rocket engine additively manufactured component, the life of the rocket engine additively manufactured component is predicted based on the third model, and the simulation part is guided according to the fatigue test, the relevant design structure of the simulation part is optimized based on the results of the fatigue test of the additively manufactured component. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings are incorporated into and constitute a part of the specification, illustrate embodiments consistent with the present disclosure, and together with the specification, are used to explain the principles of the present disclosure. Obviously, the drawings described below are only some embodiments of the present disclosure, and those skilled in the art can derive other drawings based on these drawings without inventive effort.
[0022] Figure 1 1 is a flow chart of a multi-level prediction method for fatigue life of rocket engine additively manufactured components in one embodiment of the present disclosure. DETAILED DESCRIPTION
[0023] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concepts of the example embodiments to those skilled in the art. Like reference numerals in the figures represent identical or similar structures, and thus their detailed descriptions will be omitted. Furthermore, the figures are merely schematic illustrations of the present disclosure and are not necessarily drawn to scale.
[0024] In the field of rocket engines, accurate predictions of the lifespan of additively manufactured rocket engines under complex loads are necessary. However, due to issues such as internal defects, surface quality, and the influence of molding direction in rocket engine additively manufactured components, fatigue life has a large dispersion, strength-life verification faces technical bottlenecks, and there is a lack of advanced strength theories and methods to support the engineering of additive manufacturing technology. Furthermore, due to the three-dimensional, integrated molding characteristics of rocket engine additive manufacturing, the resulting molded structures are non-uniform, anisotropic, and dependent on the scanning path and process at each point. As a result, material-level mechanical testing may be unable to predict the mechanical properties of the structure.
[0025] Based on this, see Figure 1This application discloses a multi-level prediction method for fatigue life of rocket engine additively manufactured components, comprising:
[0026] S1: Multiple sampling is performed on the additively manufactured component, and standard test pieces are processed based on the sampling;
[0027] S2: Simulate the standard test piece and establish the first model;
[0028] S3: establishing a second model based on the first model, and manufacturing a simulation part based on the second model;
[0029] S4: Testing the simulated part to form a third model, and verifying and optimizing the first model based on the third model;
[0030] S5: Perform fatigue tests on rocket engine additively manufactured components, predict the life of rocket engine additively manufactured components based on the third model, and guide simulation parts based on fatigue tests.
[0031] In the disclosed embodiment, life analysis is performed on three levels: standard test pieces, simulation pieces, and rocket engine additively manufactured components. The standard test pieces are verified and optimized through a third model formed by the simulation pieces, and the simulation pieces are verified and optimized through fatigue test results of rocket engine additively manufactured components. This allows the life prediction model of rocket engine additively manufactured components to be continuously verified and optimized at different levels. Finally, the verified and optimized life prediction model is applied to the life analysis of the overall structure of the rocket engine additively manufactured, thereby solving the problem that rocket engine additively manufactured components are difficult to predict due to the dispersion of structural performance.
[0032] It should be noted that the multi-level prediction method for fatigue life of rocket engine additively manufactured components proposed in the embodiment of the present disclosure can also be applied to the fatigue life research of other additively manufactured structures of the engine.
[0033] In some embodiments of the present disclosure, multiple sampling is performed on the additively manufactured component, and before a standard test piece is processed based on the sampling, the actual load of the additively manufactured component is determined according to a force transmission device, and multiple sampling is performed along the actual load direction.
[0034] Specifically, a force transmission device is used to determine the actual load on the additively manufactured component. Based on the determined actual load, multiple samples are taken along the actual load direction. Based on the sampling results, standard test pieces are prepared for fatigue performance testing. These standard test pieces can be categorized as quasi-static tensile standard test pieces, low-cycle fatigue standard test pieces, high-cycle fatigue standard test pieces, and expansion coefficient test standard test pieces.
[0035] In some embodiments of the present disclosure, when simulating standard test pieces (for example, quasi-static tensile standard test pieces, low-cycle fatigue standard test pieces, high-cycle fatigue standard test pieces, and expansion coefficient test standard test pieces) to establish a first model, the expansion coefficient, quasi-static tensile, high- and low-cycle fatigue of the corresponding standard test pieces are tested at different temperatures to obtain relevant parameters, and a finite element model is established based on the relevant parameters.
[0036] Specifically, standard test pieces are tested for expansion coefficient at room temperature and service temperature, as well as quasi-static tensile tests, low-cycle fatigue tests, and high-cycle fatigue tests (quasi-static tensile standard test pieces correspond to quasi-static tensile tests; low-cycle fatigue standard test pieces correspond to low-cycle fatigue tests; high-cycle fatigue standard test pieces correspond to high-cycle fatigue tests, and expansion coefficient test standard test pieces correspond to expansion coefficient tests) to determine the performance parameters and curves of the additively manufactured component to be predicted. Among them, yield strength, tensile strength, elastic modulus, Poisson's ratio, and thermal expansion coefficient are mechanical performance parameters; stress-life curves are indicators of high-cycle fatigue performance; and strain energy density-life curves are indicators of low-cycle fatigue performance.
[0037] In some embodiments of the present disclosure, when simulating a standard test piece to establish a first model, the standard test piece is tested to obtain corresponding mechanical performance parameters and fatigue performance indicators to establish the first model. Specifically, based on the mechanical performance parameters and fatigue performance indicator parameters obtained in the test, a cyclic fatigue simulation is performed on the standard test piece to establish the first model.
[0038] As an example, a finite element model of a standard test piece can be established in finite element analysis software ABAQUS. Based on the mechanical performance parameters and fatigue performance indicator parameters obtained from the test, a cyclic fatigue simulation is performed on the standard test piece to establish a first model.
[0039] In an embodiment of the present disclosure, the first model may be a fatigue viscoplastic damage evolution life prediction model.
[0040] In some embodiments of the present disclosure, when establishing a second model based on a first model and manufacturing a simulation part based on the second model, a simulation model of an additive manufacturing component is first established based on the first model, the simulation model is tested to obtain a second model, and the simulation part is designed and manufactured based on the second model.
[0041] In the embodiment of the present disclosure, the second model may be a simulation result of rocket engine additive manufacturing.
[0042] Specifically, based on the first model, a thermomechanical simulation model of the rocket engine AM integrated component was established, and the geometric model of the rocket engine AM integrated component was simulated. The results of the simulation model formed a second model. Based on the second model, the hazardous areas and load spectrum of the rocket engine AM integrated device were determined, providing a design basis for the production of a simulated component for the rocket engine AM integrated device. Based on the determined hazardous area load spectrum, the simulated component of the rocket engine AM integrated component was designed in conjunction with the equivalent design principle.
[0043] In some embodiments of the present disclosure, when the simulation part is tested to form a third model and the first model is verified and optimized based on the third model, a fatigue performance test is performed on the simulation part to form the third model.
[0044] In some embodiments of the present disclosure, a simulation part is tested to form a third model, and when the first model is verified and optimized based on the third model, the relevant parameters of the first model are verified based on the third model, and the selection of standard test piece materials is guided by the third model.
[0045] Specifically, the first model is verified and optimized in combination with the third model. For example, the deviation between the test results of the third model and the first model is verified, and the first model is corrected based on the deviation, so that the standard test piece can be optimized (for example, material optimization) using the first model.
[0046] In some embodiments of the present disclosure, when fatigue testing is performed on an additively manufactured rocket engine component, the life of the component is predicted based on the third model, and a simulated component is verified and optimized based on the fatigue testing, the life of the additively manufactured component is measured to be between 175,000 and 176,000 cycles. For example, the life of the additively manufactured component is 175,000, 175,500, or 176,000 cycles, etc.
[0047] In some embodiments of the present disclosure, when fatigue testing is performed on additively manufactured components of a rocket engine, the life of the additively manufactured components of the rocket engine is predicted based on a third model, and the simulated parts are guided by the fatigue test, the prediction of the life of the additively manufactured components by the third model formed by the simulated parts is verified based on the results of the fatigue test of the additively manufactured components.
[0048] Specifically, fatigue simulation is performed on the additively manufactured component of the rocket engine using simulation software, and the test results of the fatigue simulation of the additively manufactured component are compared with the third model formed by the simulation part to verify the third model.
[0049] In some embodiments of the present disclosure, when fatigue testing is performed on rocket engine additively manufactured components, the life of the rocket engine additively manufactured components is predicted based on the third model, and the simulation parts are guided according to the fatigue test, the relevant design structure of the simulation parts is optimized based on the results of the fatigue test of the additively manufactured components.
[0050] Specifically, fatigue simulation of the additively manufactured components of the rocket engine is performed using simulation software. The test results of the fatigue simulation of the additively manufactured components are compared with the third model formed by the simulation part, and the relevant structures of the simulation can be optimized.
[0051] As an example, fatigue simulations of additively manufactured components in rocket engines can be performed in Fe-safe.
[0052] Another aspect of the present disclosure provides a multi-level fatigue life prediction system for rocket engine additively manufactured components.
[0053] Specifically, the prediction system can test the simulation component to establish a third model, and verify and optimize the first model based on the third model.
[0054] The prediction system can also learn from the predicted lifespans of different AM-manufactured integrated rocket engine components. By comparing these predicted results with the actual conditions of these components in actual applications, relevant parameters are generated. These parameters are then used to guide the third model in verifying and optimizing the first model. This improves the accuracy of predictions for AM-manufactured rocket engine components.
[0055] Similarly, the prediction system can also verify and optimize the first model based on the prediction results of the life of different rocket engine additively manufactured integrated components, and then the second model can be established through the first model. In this way, the accuracy of the prediction of rocket engine additively manufactured components can be further improved. After considering the specification and practicing the invention disclosed herein, those skilled in the art will easily think of other embodiments of the present disclosure. This application is intended to cover any variations, uses or adaptive changes of the present disclosure, which follow the general principles of the present disclosure and include common knowledge or customary technical means in the field of this technology that are not disclosed in the present disclosure. The description and examples are to be regarded as exemplary only, and the true scope and spirit of the present disclosure are indicated by the appended claims.
Claims
1. A multi-level prediction method for fatigue life of rocket engine additive manufacturing components, characterized in that: include: Take multiple samples on the additively manufactured component and process standard test pieces based on the samples; Performing simulation on the standard test piece to establish a first model; Building a second model based on the first model, and manufacturing a simulation part based on the second model; Testing the simulation component to form a third model, and verifying and optimizing the first model based on the third model; Fatigue testing is performed on the rocket engine additively manufactured component, the life of the rocket engine additively manufactured component is predicted based on the third model, and the simulation part is guided according to the fatigue test.
2. The multi-level prediction method for fatigue life of rocket engine additive manufacturing components according to claim 1 is characterized in that: Before sampling multiple times on the additively manufactured component and processing a standard test piece based on the sampling, the actual load of the additively manufactured component is determined according to the force transmission device, and multiple samplings are performed along the actual load direction.
3. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 1, characterized in that: When simulating the standard test piece and establishing the first model, the expansion coefficient, quasi-static stretching, high and low cycle fatigue of the standard test piece at different temperatures are tested to obtain relevant parameters, and a finite element model is established based on the relevant parameters.
4. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 3, characterized in that: When simulating the standard test piece and establishing the first model, the standard test piece is tested to obtain corresponding mechanical performance parameters and fatigue performance indicators to establish the first model.
5. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 1, characterized in that: When establishing a second model based on the first model and manufacturing a simulation part based on the second model, first establish an additive manufacturing component simulation model based on the first model, test the simulation model to obtain the second model, and design and manufacture the simulation part based on the second model.
6. The multi-level prediction method for fatigue life of rocket engine additive manufacturing components according to claim 1, characterized in that: When the simulation part is tested to form a third model, and the first model is verified and optimized based on the third model, a fatigue performance test is performed on the simulation part to form a third model.
7. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 1, characterized in that: The simulation part is tested to form a third model, and when the first model is verified and optimized according to the third model, the relevant parameters of the first model are verified according to the third model, and the selection of the material of the standard test piece is guided according to the third model.
8. The multi-level prediction method for fatigue life of rocket engine additive manufacturing components according to claim 1, characterized in that: When fatigue testing was performed on the additively manufactured components of the rocket engine, the life of the additively manufactured components of the rocket engine was predicted based on the third model, and the simulation parts were verified and optimized according to the fatigue test, the life of the additively manufactured components was measured to be between 175,000 and 176,000 times.
9. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 1, characterized in that: When fatigue testing is performed on the additively manufactured components of a rocket engine, the life of the additively manufactured components of the rocket engine is predicted based on the third model, and the simulation part is guided according to the fatigue test, the prediction of the life of the additively manufactured components by the third model formed by the simulation part is verified based on the results of the fatigue test of the additively manufactured components.
10. The multi-level prediction method for fatigue life of rocket engine additively manufactured components according to claim 1, characterized in that: When fatigue testing is performed on the additively manufactured components of a rocket engine, the life of the additively manufactured components of the rocket engine is predicted based on the third model, and the simulation component is guided according to the fatigue test, the relevant design structure of the simulation component is optimized based on the results of the fatigue test of the additively manufactured components.