Crack fault blade improvement and optimization method

Abstract

The invention relates to the field of blade optimization, in particular to a crack fault blade improvement and optimization method. Obtaining the size and position information of the crack; the cracks with the crack sizes smaller than a first threshold value are eliminated, and first optimized cracks are obtained through screening; constructing a three-dimensional model of the blade, and performing finite element analysis on the three-dimensional model of the blade to obtain first data of the blade; constructing a crack blade model; performing finite element analysis on the crack blade model to obtain second data; comparing the second data with the first data, and screening to obtain a second optimized crack; performing blade molded line improvement on the three-dimensional model of the blade in the area where the second optimized crack is located, and outputting the improved model; performing finite element analysis on the improved model to obtain third data; the third data is compared with the first data, improvement and optimization are completed, the traditional development period is greatly shortened, and the problem of high cost caused by multiple times of trial production is solved.

Description

Technical Field

[0001] This invention relates to the field of blade optimization, and specifically to a method for improving and optimizing blades with cracked defects. Background Technology

[0002] Blades are crucial components of rotating machinery, especially in high-power equipment. They are typically arranged in a circumferential ring and operate in environments characterized by high speeds, high temperatures, and complex variable loads. This places extremely high demands on the material properties, structural design, manufacturing processes, and assembly precision of the blades. However, under the impact of high-temperature, high-speed gas and the long-term erosion of corrosive media, the blade surface is prone to cracks and defects. This failure not only significantly reduces aerodynamic efficiency and wastes energy but can also lead to stress concentration, causing crack propagation and even blade breakage, resulting in unplanned downtime. This severely impacts the overall safety and operational economy of the machine, leading to significant production losses and maintenance costs.

[0003] Currently, in engineering applications, crack testing is mainly conducted on actual blades, and the collected test data is used to optimize blade morphology and materials. While this method is intuitive and effective, it has significant limitations: the tests require specialized equipment, are time-consuming and costly, and the damage tests are destructive and difficult to replicate on a large scale; furthermore, the control of conditions and the range of parameter variations in physical tests are limited, restricting the efficiency of design iteration and scheme comparison; as modern rotating machinery develops towards higher parameters and greater reliability, traditional testing methods can no longer meet the practical engineering needs of rapid research and development and real-time optimization. Summary of the Invention

[0004] To address the problems mentioned in the prior art, this invention proposes an improvement and optimization method for cracked blades. This method combines numerical calculation and screening to improve and optimize cracked blades, thereby solving the problems in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: This invention discloses an improvement and optimization method for cracked blades, comprising the following steps: S1. Map the blade with crack faults to obtain information on the size and location of the cracks; S2. Based on the size and location information of the crack, cracks with a size smaller than the first threshold are excluded, and the first optimized crack is obtained. S3. Construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. S4. Introduce the first optimized crack into the three-dimensional model of the blade to construct the cracked blade model; S5. Perform finite element analysis on the cracked blade model to obtain the second data; compare the second data with the first data, and perform the second screening based on the preset temperature and stress to exclude the cracks in the first optimized cracks whose performance does not exceed the limit, and obtain the second optimized cracks. S6. Improve the blade profile of the 3D model of the blade where the second optimized crack is located, and output the improved model. S7. Perform finite element analysis on the improved model to obtain the third data; compare the third data with the first data. If the predetermined requirements are not met, repeat S6 and S7 until the predetermined requirements are met; if the predetermined requirements are met, the improvement and optimization are completed.

[0006] As a further improvement of the present invention, the size of the crack in S2 is the length of the crack; The first threshold in S2 is the ratio condition of crack length H to blade length L, and the ratio condition is H < 1 / 20 L.

[0007] As a further improvement of the present invention, the first optimized crack in S2 is a crack with the maximum length, maximum width and maximum depth.

[0008] As a further improvement to the present invention, S4, "introducing the first optimized crack into the three-dimensional model of the blade to construct a cracked blade model," includes: Boolean subtraction operations were performed on the three-dimensional model of the blade using an elliptical cylinder to cut out the first optimized crack.

[0009] As a further improvement to the present invention, the parameters of the elliptical cylinder include: The maximum length of the first optimized crack is taken as the major axis diameter of the ellipse, the maximum width of the first optimized crack is taken as the minor axis diameter of the ellipse, and the maximum depth of the first optimized crack is taken as the height of the elliptical cylinder.

[0010] As a further improvement of the present invention, step S5 includes, based on a preset temperature and stress: The temperature value in the cracked area is not higher than the corresponding temperature value in the first data; The stress value is no greater than 110% of the corresponding stress value in the first data.

[0011] As a further improvement to the present invention, the improvement of the blade profile in S6 includes: In the region where the second optimized crack is located, a local thickening process is performed with the crack center as the reference, and the amount of thickening is determined according to the depth of the crack.

[0012] This invention proposes an improvement and optimization system for cracked blades, comprising: The mapping module is used to map the blades with crack faults and obtain information on the size and location of the cracks. The first screening module excludes cracks with a size smaller than a first threshold based on the size and location information of the crack, and selects the first optimized crack. The first construction module is used to construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. The second building module is used to introduce the first optimized crack into the three-dimensional model of the blade to build the cracked blade model. The analysis module is used to perform finite element analysis on the cracked blade model to obtain the second data; the second data is compared with the first data, and a second screening is performed based on the preset temperature and stress to exclude cracks in the first optimized crack whose performance does not exceed the limit, and to obtain the second optimized crack. The improvement module is used to improve the blade profile of the 3D model of the blade where the second optimization crack is located, and output the improved model. The optimization module is used to perform finite element analysis on the improved model to obtain the third data. The third data is compared with the first data. If the predetermined requirements are not met, S6 and S7 are repeated until the predetermined requirements are met. If the predetermined requirements are met, the improvement and optimization are completed.

[0013] This invention proposes an improvement and optimization device for cracked blades, comprising a processor and a memory, wherein the processor executes a computer program stored in the memory to implement the above-described method for improving and optimizing cracked blades.

[0014] This invention proposes a computer-readable storage medium for storing a computer program, wherein the computer program, when executed by a processor, implements the aforementioned method for improving and optimizing cracked blades.

[0015] Compared with the prior art, the present invention achieves the following technical effects: This invention acquires crack size and location information through mapping, enabling quantitative identification and localization of cracks. By setting a first threshold to initially screen and exclude micro-cracks, focusing on the first optimized crack, subsequent analysis efficiency is further improved. A three-dimensional blade model is constructed and finite element analysis is performed to obtain first data under crack-free conditions as basic data. The first optimized crack is introduced into the three-dimensional model using Boolean subtraction of elliptical cylinders to construct a cracked blade model, enhancing simulation realism. Finite element analysis of the cracked blade model yields second data, which is compared with the first data. Combined with temperature and stress thresholds, a second screening step identifies the second optimized crack that significantly impacts performance. Targeted structural reinforcement of the cracked region is achieved by improving the blade profile in the second optimized crack area. Iterative model improvement and finite element verification continue until the third data meets predetermined requirements, ensuring that the optimized model recovers or surpasses the crack-free state in temperature and stress performance. This method solves the problems of high cost, long cycle, high destructiveness, and limited parameter range inherent in traditional experimental methods. This method combines numerical simulation and iterative optimization to improve the structure of cracked blades, avoiding the high cost, long cycle and destructive defects of traditional experimental methods, and improving the efficiency and reliability of blade failure treatment. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall process of the present invention. Detailed Implementation

[0017] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0018] See Figure 1 This invention proposes an improvement and optimization method for cracked blades, comprising the following steps: S1. Map the blade with crack faults to obtain information on the size and location of the cracks; S2. Based on the size and location information of the crack, cracks with a size smaller than the first threshold are excluded, and the first optimized crack is obtained. S3. Construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. S4. Introduce the first optimized crack into the three-dimensional model of the blade to construct the cracked blade model; S5. Perform finite element analysis on the cracked blade model to obtain the second data; compare the second data with the first data, and perform the second screening based on the preset temperature and stress to exclude the cracks in the first optimized cracks whose performance does not exceed the limit, and obtain the second optimized cracks. S6. Improve the blade profile of the 3D model of the blade where the second optimized crack is located, and output the improved model. S7. Perform finite element analysis on the improved model to obtain the third data; compare the third data with the first data. If the predetermined requirements are not met, repeat S6 and S7 until the predetermined requirements are met; if the predetermined requirements are met, the improvement and optimization are completed.

[0019] The present invention will be further explained below with reference to the accompanying drawings and specific embodiments: This invention provides an improvement and optimization method for cracked blades by introducing numerical simulation and multi-level screening strategies, which significantly improves design iteration efficiency and engineering applicability.

[0020] Step 1: First, perform high-precision 3D scanning or optical measurement on the blade with cracks to obtain the blade's geometry and the size (such as length, width, and depth) and location information of the surface cracks. Specifically, in this embodiment, laser scanners, structured light scanning systems, or industrial CT scanners are typically used for mapping to ensure the accuracy and completeness of the data.

[0021] Step 2: Set a first threshold based on the size and location information of the crack. In this embodiment, the first threshold is specifically the ratio of crack length H to the total blade length L, where H < 1 / 20L. By comparing with the first threshold, cracks that are too small or whose impact on structural performance is negligible can be eliminated. Therefore, the selected "first optimized cracks" are usually those with larger sizes that may cause stress concentration. These cracks can be the maximum length H. max The crack, or the maximum width I max The crack, or the maximum depth G max Cracks.

[0022] In this embodiment, this step specifically uses size screening to select cracks that are truly valuable for optimization and use them for research and calculation, thus avoiding a waste of subsequent computing resources due to too many types of cracks.

[0023] Step 3: A 3D model of the crack-free blade is constructed using CAD software. Finite element analysis is then performed on the 3D model to simulate the blade's temperature field, stress field, vibration modes, and other parameters under actual operating conditions. This data serves as the primary data, representing the baseline data for the crack-free state of the blade. This step establishes a healthy model of the blade, providing a basis for subsequent comparative analysis after cracks are introduced.

[0024] Step 4: Introduce the selected first optimized crack into the 3D model using Boolean operations. Specifically, use an elliptical cylinder as the cutting tool, with the major axis diameter 'a' corresponding to the maximum crack length 'H'. max The minor axis diameter b of the elliptical cylinder corresponds to the maximum width I. max The height C of the major axis of the elliptical cylinder corresponds to the maximum depth G. max This process involves cutting the 3D model of the blade to create a crack model with a realistic shape. This step reproduces the crack morphology through geometric modeling, providing realistic input for subsequent finite element analysis.

[0025] Step 5: Perform finite element analysis again on the cracked blade model to obtain second data, which is the performance data under the cracked state. Compare the second data with the first data and perform a second screening according to preset conditions. In this embodiment, the preset conditions are that the temperature in the cracked area is not higher than the baseline data and the stress does not exceed 110% of the baseline data. The second screening of the cracked blade can eliminate those cracks that are large in size but do not cause significant performance degradation, and retain the second optimized cracks that really need to be optimized. Through the second screening, the cracks that have the greatest impact on the blade's safety and lifespan are further screened.

[0026] Step 6: For the area where the second optimization crack is located, perform local structural reinforcement. Usually, the blade profile in this area is thickened based on the crack center. The amount of thickening is dynamically adjusted according to the crack depth. For example, the greater the depth, the more thickening is required. This step can be quickly iterated and modified using parametric CAD tools.

[0027] Step 7: Perform finite element analysis on the optimized model again to obtain third data, and compare it with the first data. If the performance indicators, such as maximum stress, temperature distribution, vibration frequency, etc., do not meet the predetermined requirements, return to Step 6 to further adjust the thickness or optimize the region; if the requirements are met, output the final optimized model. This step uses a closed-loop iterative mechanism to ensure the effectiveness and reliability of the optimization scheme and avoid over-design or under-design.

[0028] Traditional methods for treating blade cracks require specialized equipment, are time-consuming, and costly. The method of this invention improves crack research through numerical simulation and data analysis, thereby greatly reducing reliance on physical experiments and eliminating the need for numerous tedious physical tests, thus effectively saving experimental costs. In addition, by acquiring information about blade cracks and combining it with crack analysis mechanisms, crack results are obtained. Based on the crack analysis results, it is ensured that the treatment measures can effectively eliminate potential crack hazards without causing unnecessary damage to the blade, thus greatly improving the targeting and effectiveness of crack treatment. Based on the same inventive concept, this invention also provides an improvement and optimization system for cracked blades. Since the principle of this improvement and optimization system for cracked blades is similar to that of the aforementioned improvement and optimization method for cracked blades, the implementation of this improvement and optimization system for cracked blades can refer to the implementation of the improvement and optimization method for cracked blades, and the repeated parts will not be described again.

[0029] In specific implementation, the crack-faulted blade improvement and optimization system provided in this embodiment of the invention specifically includes: The mapping module is used to map the blades with crack faults and obtain information on the size and location of the cracks. The first screening module excludes cracks with a size smaller than a first threshold based on the size and location information of the crack, and selects the first optimized crack. The first construction module is used to construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. The second building module is used to introduce the first optimized crack into the three-dimensional model of the blade to build the cracked blade model. The analysis module is used to perform finite element analysis on the cracked blade model to obtain the second data; the second data is compared with the first data, and a second screening is performed based on the preset temperature and stress to exclude cracks in the first optimized crack whose performance does not exceed the limit, and to obtain the second optimized crack. The improvement module is used to improve the blade profile of the 3D model of the blade where the second optimization crack is located, and output the improved model. The optimization module is used to perform finite element analysis on the improved model to obtain the third data. The third data is compared with the first data. If the predetermined requirements are not met, S6 and S7 are repeated until the predetermined requirements are met. If the predetermined requirements are met, the improvement and optimization are completed.

[0030] Accordingly, this embodiment of the invention also provides a device for improving and optimizing cracked blades, including a processor and a memory, wherein the processor executes a computer program stored in the memory to implement the method for improving and optimizing cracked blades as provided in this embodiment of the invention.

[0031] For more detailed information on the above methods, please refer to the relevant content disclosed in the foregoing embodiments, which will not be repeated here.

[0032] Accordingly, embodiments of the present invention also provide a computer-readable storage medium for storing a computer program, wherein the computer program, when executed by a processor, implements the above-described improved and optimized method for cracked blades provided in embodiments of the present invention.

[0033] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems, devices, and storage media disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to the method section.

[0034] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0035] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly by hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.

[0036] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0037] The above provides a detailed description of the method, system, equipment, and storage medium for improving and optimizing cracked blades provided by this invention. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this invention. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method for improving and optimizing a blade with cracked defects, characterized in that, Includes the following steps: S1. Map the blade with crack faults to obtain information on the size and location of the cracks; S2. Based on the size and location information of the crack, cracks with a size smaller than the first threshold are excluded, and the first optimized crack is obtained. S3. Construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. S4. Introduce the first optimized crack into the three-dimensional model of the blade to construct the cracked blade model; S5. Perform finite element analysis on the cracked blade model to obtain the second data; The second data is compared with the first data, and a second screening is performed based on the preset temperature and stress. Cracks whose performance does not exceed the limit in the first optimized crack are excluded, and the second optimized crack is obtained. S6. Improve the blade profile of the 3D model of the blade where the second optimized crack is located, and output the improved model. S7. Perform finite element analysis on the improved model to obtain the third data; The third data is compared with the first data. If the predetermined requirements are not met, S6 and S7 are repeated until the predetermined requirements are met. If the predetermined requirements are met, the improvement and optimization are completed.

2. The method for improving and optimizing a cracked blade according to claim 1, characterized in that, The size of the crack in S2 is the length of the crack; The first threshold in S2 is the ratio condition of crack length H to blade length L, and the ratio condition is H < 1 / 20 L.

3. The method for improving and optimizing a cracked blade according to claim 1, characterized in that, The first optimized crack in S2 is the crack with the maximum length, maximum width, and maximum depth.

4. The method for improving and optimizing a cracked blade according to claim 1, characterized in that, The step S4, "introducing the first optimized crack into the three-dimensional model of the blade to construct a cracked blade model," includes: Boolean subtraction operations were performed on the three-dimensional model of the blade using an elliptical cylinder to cut out the first optimized crack.

5. The method for improving and optimizing a cracked blade according to claim 4, characterized in that, The parameters of the elliptical cylinder include: The maximum length of the first optimized crack is taken as the major axis diameter of the ellipse, the maximum width of the first optimized crack is taken as the minor axis diameter of the ellipse, and the maximum depth of the first optimized crack is taken as the height of the elliptical cylinder.

6. The method for improving and optimizing a cracked blade according to claim 1, characterized in that, S5 includes, based on preset temperature and stress: The temperature value in the cracked area is not higher than the corresponding temperature value in the first data; The stress value is no greater than 110% of the corresponding stress value in the first data.

7. The method for improving and optimizing a cracked blade according to claim 1, characterized in that, The improvements to the blade profile in S6 include: In the region where the second optimized crack is located, a local thickening process is performed with the crack center as the reference, and the amount of thickening is determined according to the depth of the crack.

8. A system for improving and optimizing cracked blades, characterized in that, include: The mapping module is used to map the blades with crack faults and obtain information on the size and location of the cracks. The first screening module excludes cracks with a size smaller than a first threshold based on the size and location information of the crack, and selects the first optimized crack. The first construction module is used to construct a three-dimensional model of the blade and perform finite element analysis on the three-dimensional model of the blade to obtain the first data of the blade. The second building module is used to introduce the first optimized crack into the three-dimensional model of the blade to build the cracked blade model. The analysis module is used to perform finite element analysis on the cracked blade model to obtain the second data. The second data is compared with the first data, and a second screening is performed based on the preset temperature and stress. Cracks whose performance does not exceed the limit in the first optimized crack are excluded, and the second optimized crack is obtained. The improvement module is used to improve the blade profile of the 3D model of the blade where the second optimization crack is located, and output the improved model. The optimization module is used to perform finite element analysis on the improved model to obtain third-party data. The third data is compared with the first data. If the predetermined requirements are not met, S6 and S7 are repeated until the predetermined requirements are met. If the predetermined requirements are met, the improvement and optimization are completed.

9. A device for improving and optimizing cracked blades, characterized in that, It includes a processor and a memory, wherein the processor executes a computer program stored in the memory to implement the improved and optimized method for cracked blades as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, Used to store a computer program, wherein the computer program, when executed by a processor, implements the improved and optimized method for cracked blades as described in any one of claims 1 to 7.

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