Turbine rotor time sequence collaborative life verification method and system and storage medium
The time-sequential life verification method for multiple components of a turbine rotor based on the separation principle uses multiple sets of baffle test pieces to alternately verify the life of the turbine disk and the baffle, which solves the problem of baffle over-testing in turbine rotor life verification, and realizes accurate life verification of the turbine disk and improves the utilization rate of test pieces.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- AECC HUNAN AVIATION POWERPLANT RES INST
- Filing Date
- 2026-01-12
- Publication Date
- 2026-05-12
Smart Images
Figure CN122020883A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of aero-engine technology, and specifically relates to a method, system and storage medium for verifying the time-series coordinated life of a turbine rotor. Background Technology
[0002] Turbine disks and baffles are common structural forms used in advanced aero-engine gas turbine rotors. Low-cycle fatigue tests of turbine disks are usually conducted on vertical rotating test chambers. Because component test chambers cannot simulate the temperature loads of the engine under actual operating conditions, uniform temperature fields are typically used for testing. However, this makes it difficult to completely reproduce the non-uniform temperature distribution and thermal stress in the engine. A uniform temperature field eliminates the influence of temperature gradients on the thermal stress of the wheel center. Generally, it is necessary to increase the test speed to ensure that the stress level of the wheel center under test conditions is comparable to that of the engine under operating conditions.
[0003] Because the local stress in key areas of the baffle is not significantly affected by the temperature gradient, the stress levels in these areas are relatively high, often exceeding the test threshold. Furthermore, the gas turbine disk and baffle are typically tested as a complete rotor test piece with the same life performance indicators, making the baffle that has exceeded the test threshold relatively more prone to fatigue failure.
[0004] To verify the safe life reserve of the gas turbine rotor, after completing the test verification of the design life index, life potential tapping tests are usually carried out to gradually verify the safe life of the gas turbine rotor. If the turbine disc center, tenon groove, eccentric hole, as well as the stop, bolt hole, and ventilation groove on the baffle are tested at the same time, it will lead to too many baffles being tested, which greatly increases the risk of fatigue failure. Summary of the Invention
[0005] To address the above problems, this invention provides a method for verifying the timing-coordinated lifespan of a turbine rotor, the method comprising: Determine the stress coefficient of the pre-tested part of the turbine disk-baffle assembly under the upper limit speed condition of fatigue test; The number of test cycles required to verify the turbine disk-baffle assembly to the predetermined target safe life index is determined based on the stress coefficient. The timing of baffle assembly replacement and reassembly is determined based on the number of test cycles. A sequential life test, including component replacement, is performed on the turbine disk-baffle assembly according to the replacement and reassembly time points; After completing the sequential life test, it is determined whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
[0006] Furthermore, the determination of the stress coefficient of the pre-tested part of the turbine disk-baffle assembly includes: The equivalent stress of the pre-tested part under the upper limit speed of the fatigue test was obtained by finite element analysis. Based on the equivalent stress and material property data of the turbine disk-baffle assembly, the stress coefficient is calculated, which characterizes the fatigue damage rate of the pre-tested part under test conditions.
[0007] Furthermore, the formula for calculating the number of test cycles is as follows:
[0008] in, N i This indicates the number of test cycles required for the turbine disk-baffle assembly to be verified to the predetermined target safe life index. K Indicates the lifetime dispersion factor. N f Indicates the predetermined target safe life index. a Indicates the stress coefficient. p This indicates the fatigue characteristic index.
[0009] Furthermore, determining the timing of the replacement and reassembly of the baffle assembly includes: Based on the difference in the number of test cycles required for the baffle assembly and turbine disk to achieve their respective verification targets, the timing for replacing and reinstalling the baffle assembly is determined.
[0010] Furthermore, the sequential lifetime test includes: When the baffle assembly reaches the number of test cycles required to verify the target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the target safe life index of the baffle assembly is verified. Install the new baffle, pause the test when the turbine disk reaches the number of test cycles required to verify the target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the target safe life index of the turbine disk.
[0011] Furthermore, determining the timing of the replacement and reassembly of the baffle assembly includes: Set multiple predetermined target safety life indicators for the turbine disk-baffle assembly to be verified, including previous target safety life indicators and subsequent target safety life indicators; Calculate the number of test cycles required to verify the turbine disk and baffle assembly to each predetermined target safety life index; When the next target safety life index is verified, the replacement and reinstallation time nodes of the baffle assembly are determined based on the number of test cycles required to verify the baffle assembly to the next target safety life index, the number of test cycles required to verify the baffle assembly to the previous target safety life index, and the number of test cycles required to verify the turbine disk to the previous target safety life index. According to the replacement and reinstallation time nodes, a multi-stage time-series coordinated life test including the replacement of the baffle assembly is performed.
[0012] Furthermore, the multi-stage time-series co-living test includes: When the baffle assembly reaches the number of test cycles required for the previous verification target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the previous target safe life index of the baffle assembly is verified. Install a new baffle, pause the test when the turbine disk reaches the number of test cycles required for the previous verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the previous target safe life index of the turbine disk. Reassemble the baffle assembly, pause the test when the baffle assembly reaches the number of test cycles required for the next verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the safety life index of the baffle assembly for the next target. The new baffle is installed, and the test is paused when the turbine disk reaches the number of test cycles required for the next verification target. The turbine disk-baffle assembly is disassembled for non-destructive testing to verify the turbine disk's next target safe life index.
[0013] Furthermore, the verification result determination also includes: After completing the sequential life test, if it is necessary to verify the actual safe life of the turbine disk-baffle assembly, the baffle assembly is reinstalled and the test continues with the turbine disk until the full life test cycle number is reached. The test was paused when the turbine disk-baffle assembly reached the full life test cycle number to verify the actual life of the turbine disk-baffle assembly.
[0014] This invention also provides a turbine rotor time-series coordinated life testing system, the system comprising a coefficient determination module, a cycle number determination module, a time determination module, a testing module, and a verification module. The coefficient determination module is configured to determine the stress coefficient of the turbine disk-baffle assembly pre-tested part under the upper limit speed of the fatigue test; The cycle number determination module is configured to determine the number of test cycles required to verify the turbine disk-baffle assembly to a predetermined target safe life index based on the stress coefficient. The time determination module is configured to determine the replacement and reassembly time points of the baffle assembly based on the number of test cycles; The test module is configured to perform a sequential life test, including component replacement, on the turbine disk-baffle assembly according to the replacement and reassembly time points; The verification module is configured to determine, after the sequential life test is completed, whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
[0015] The present invention also provides a computer storage medium storing one or more instructions that, when executed by one or more computers, cause the one or more computers to perform the method described in the present invention.
[0016] Compared with the prior art, the present invention has the following advantages: This invention discloses a method, system, and storage medium for verifying the time-series coordinated lifespan of a turbine rotor. It proposes a method for verifying the time-series coordinated lifespan of multiple components of a turbine rotor based on the separation principle. By employing multiple sets of baffle test specimens, alternately used as test specimens or auxiliary test specimens, the time-series coordinated lifespan verification of multiple components of a gas turbine rotor is achieved. Using the test scheme of this invention, premature failure of the baffle test specimens due to over-testing can be effectively avoided, effectively solving the problem of coordinated verification of the turbine disk-baffle assembly.
[0017] This invention decomposes the turbine rotor system into "long-life turbine disk components" and "short-life replaceable components such as baffles" for time-sequential verification, breaking the limitation of traditional overall testing where the system life is "vetoed" by the weakest component. It can independently verify the actual life limit of the turbine disk, avoiding the obscuring of the turbine disk's true load-bearing potential due to premature failure of auxiliary components such as baffles. The accurate life data obtained through layered verification can provide direct basis for lightweight design and performance improvement of core components such as turbine disks, avoiding weight and efficiency losses caused by overly conservative design.
[0018] This invention, through its replaceable design, allows a single turbine disk specimen to be used with multiple sets of baffles to complete multiple life cycle verifications. It transforms the overall test into a serialized verification that can be evaluated in stages and adjusted midway. Even if the verification of a certain baffle fails, it will not affect other components and subsequent verifications, greatly reducing the risk of global loss caused by single-point failure, significantly reducing test costs, and improving specimen utilization.
[0019] This invention fully verifies the long lifespan of the turbine disk and the multiple life cycles of the baffle through time-series life tests. The verification is complete and the conclusions are reliable. It fully explores the design potential and provides key data support that was previously unavailable for the development of engine maintenance programs based on actual damage data.
[0020] This invention can obtain continuous damage accumulation, crack initiation and propagation data throughout the entire life cycle by actively pausing the test, disassembling and inspecting, and replacing components at multiple preset life nodes. Through time-series collaborative verification, it can systematically obtain the interaction data between the turbine disk and the baffle at different stages.
[0021] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description, claims and drawings. Attached Figure Description
[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0023] Figure 1 A schematic flowchart of the turbine rotor timing-coordinated life verification method according to an embodiment of the present invention is shown; Figure 2 A schematic diagram of the gas turbine disk-baffle assembly structure in an embodiment of the present invention is shown; Figure 3 A schematic diagram of the key assessment positions of the gas turbine disk in an embodiment of the present invention is shown; Figure 4 A schematic diagram of the key assessment positions of the baffle assembly in an embodiment of the present invention is shown; Figure 5 A schematic diagram of the specific process of the turbine rotor timing-coordinated life verification method in an embodiment of the present invention is shown; Figure 6 A schematic diagram of the turbine rotor timing-coordinated life verification system according to an embodiment of the present invention is shown.
[0024] In the diagram: 1. Turbine disk; 2. Bolt; 3. First baffle; 4. Second baffle; 5. Wheel center; 6. Eccentric hole; 7. Throat; 8. Mortise and tenon; 9. Bolt hole; 10. Stop; 11. Vent groove. Detailed Implementation
[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0026] In existing technologies, the most widely used method for turbine rotor life verification is a one-time test of the entire rotor until the target number of cycles or the first failure. The main test procedure is as follows: Specimen preparation: All parts are assembled into a complete rotor specimen according to the engine assembly state; Load application: A simplified load spectrum simulating the engine's working cycle is applied on a rotating fatigue tester. The test is usually conducted at room temperature or uniform temperature; Test termination condition: The test continues until the target number of test cycles is reached, or the first detectable engineering crack is found through vibration monitoring, acoustic emission, or periodic disassembly inspection; Result determination: The target number of test cycles is used as a conservative estimate of the safe life of the entire rotor system. The test is terminated, and the entire rotor (including the turbine disk, which may still be intact) is disassembled for inspection or scrapped. The essence of turbine rotor life verification in existing technologies is to treat the turbine rotor as an indivisible whole for life assessment.
[0027] However, existing technologies test the gas turbine rotor as a whole until the target number of test cycles or fatigue failure occurs. This method has the following main drawbacks: the test conclusions are conservative, the verification is insufficient, and it is impossible to explore the true life limit of long-life components such as turbine discs, resulting in wasted design margins and potential suppression of product performance. The verification is incomplete. A turbine disc test piece worth hundreds of thousands or even millions of yuan may be scrapped due to the failure of a baffle worth only one-tenth or less, which is extremely uneconomical and the cost of a single test failure is huge. It is impossible to verify the reliability of detachable components (such as baffles) after reaching the first target life cycle and being inspected and reinstalled for the second life cycle. The lack of data support restricts the formulation of engine maintenance programs and the reduction of operating costs, and fails to meet the requirements of modern maintainability design. The test only provides a failure data at the final point. For understanding the damage evolution process of the turbine rotor throughout the entire life cycle and verifying the accuracy of the life models of each component, the data sample and process information provided are too singular, and the data value provided is limited.
[0028] To address the aforementioned issues, this invention proposes a time-sequential coordinated life verification method for multiple components of a gas turbine rotor based on the separation principle. This method employs multiple sets of baffle test specimens, alternating between the test specimen and the auxiliary test specimen, thereby achieving time-sequential coordinated life verification of multiple components of the gas turbine rotor. Using the test scheme of this invention effectively avoids premature failure of the baffle test specimens due to over-testing, effectively solving the problem of coordinated verification of the turbine disk-baffle assembly.
[0029] This invention proposes a time-sequential collaborative life verification method for multiple components of a turbine rotor based on the separation principle. The core of this invention lies in using the time separation principle to separate and resolve the contradictory requirements of "requiring the baffle to survive in the early stage of the test" and "requiring the baffle not to restrict the turbine disk assessment in the later stage of the test" by introducing different baffles at different time stages. This can effectively prevent the baffle test piece from failing prematurely due to over-testing and effectively solve the problems of collaborative life verification and life potential tapping verification of turbine disk-baffle assembly.
[0030] Figure 1 A schematic flowchart of the turbine rotor timing-coordinated life verification method according to an embodiment of the present invention is shown. Figure 1 In this method, the method includes: Step S1: Determine the stress coefficient of the pre-tested part of the turbine disk-baffle assembly under the upper limit speed condition of the fatigue test.
[0031] Specifically, in this embodiment of the invention, the determination of the stress coefficient of the pre-tested part of the turbine disk-baffle assembly includes: obtaining the equivalent stress of the pre-tested part under the upper limit speed of the fatigue test through finite element analysis; calculating the stress coefficient based on the equivalent stress and the material property data of the turbine disk-baffle assembly, wherein the stress coefficient characterizes the fatigue damage rate of the pre-tested part under the test conditions.
[0032] In this step, steps S11-S15 are used to specifically explain the stress coefficient of the turbine disk-baffle assembly under the condition of determining the upper limit speed of the fatigue test in the embodiment of the present invention: Step S11: Three-dimensional stress analysis and low-cycle fatigue life calculation of turbine disk-baffle assembly.
[0033] Based on typical flight missions of aircraft or helicopters, obtain the full loads on the turbine disk and baffle, including rotational speed, temperature load, aerodynamic load, and axial preload, and conduct three-dimensional stress analysis and low-cycle fatigue life calculation of the engine turbine disk and baffle.
[0034] Step S12: Select several key locations on the turbine disk and baffle as the assessment parts for the low-cycle fatigue test.
[0035] Figure 2 A schematic diagram of the gas turbine disk-baffle assembly structure in an embodiment of the present invention is shown. Figure 2 In the middle, the baffle assembly is connected to the turbine disk 1 by bolt 2. The baffle assembly includes a first baffle 3 and a second baffle 4 respectively disposed on both sides of the turbine disk 1.
[0036] Figure 3 A schematic diagram of the key assessment positions of the gas turbine disk in an embodiment of the present invention is shown. Figure 3 In the turbine disk, key testing locations include the wheel center (5), eccentric hole (6), throat (7), and tenon (8). Figure 4 A schematic diagram of the key assessment positions of the baffle assembly in an embodiment of the present invention is shown. Figure 4 In the process, the key test positions of the baffle assembly include bolt hole 9, stop 10 and vent groove 11. The baffle assembly is connected by bolt 2 passing through bolt hole 9, eccentric hole 6 and turbine disk 1 in sequence.
[0037] It should be noted that the selection of key assessment locations in this embodiment of the invention is only an illustrative example. In specific implementation, adjustments can be made to adapt to specific test requirements.
[0038] Step S13: Determine the test temperature for low-cycle fatigue testing of the turbine disk-baffle assembly specimen.
[0039] Based on the operating temperature of the main test parts of the engine condition, the test temperature for the low-cycle fatigue test of the turbine disk-baffle test piece is determined. Optionally, in this embodiment of the invention, the main test parts of the turbine disk in the engine condition include the wheel center 5, the eccentric hole 6, or the tenon groove 8.
[0040] Step S14: Determine the equivalent stress and upper limit speed of the turbine disk test area under fatigue test conditions.
[0041] Based on the principle of damage equivalence, and considering the equivalent stress in key areas of the turbine disk under engine operating conditions... To ensure the stress coefficient α of the critical area of the turbine disk under test conditions. disc The equivalent stress of the turbine disk at the main test parts is approximately 1.0, obtained under fatigue test conditions. and the upper limit speed of the test The specific calculation method is as follows: (1) (2) In equation (1), This represents the stress coefficient of the critical region of the turbine disk under test conditions. This represents the equivalent stress (MPa) of the main test components of the turbine disk under fatigue test conditions. This represents the equivalent stress in the critical area of the turbine disk during engine operation, expressed in MPa. The ultimate tensile strength of a material at the test temperature, expressed in MPa. This represents the ultimate tensile strength of a material at the engine's operating temperature, expressed in MPa.
[0042] In equation (2), This represents the functional relationship between the equivalent stress at the turbine disk test site and the test rotational speed at a certain temperature. This indicates the upper limit speed of the turbine disk in low-cycle fatigue test, in r / min.
[0043] In this step, the stress coefficient α of the critical region of the turbine disk under the test conditions is calculated using formula (1). disc Equivalent stress of the main test parts of the turbine disk under fatigue test conditions Three-dimensional finite element iterative calculation was used, and the upper limit speed n of the turbine disk during the calculation was adjusted until the equivalent stress of the main test parts of the turbine disk was obtained. At this point, the corresponding upper limit rotational speed for the test is n= .
[0044] Step S15: Determine the equivalent stress of other test parts of the turbine disk and key parts of the baffle assembly under fatigue test conditions.
[0045] Based on the equivalent stress of key parts of the baffle under engine operating conditions Equivalent stress of other parts of the turbine disk during engine operation The upper limit speed of the turbine disk in low-cycle fatigue test was obtained by finite element calculation. Equivalent stress in these parts under these conditions , The stress coefficients of key parts of the baffle and other parts of the turbine disk are calculated using the following formulas. The specific calculation method is as follows: (3) (4) (5) (6) Step S2: Determine the number of test cycles required to verify the turbine disk-baffle assembly to the predetermined target safe life index based on the stress coefficient.
[0046] Specifically, the formula for calculating the number of test cycles is as follows:
[0047] in, N i This indicates the number of test cycles required for the turbine disk-baffle assembly to be verified to the predetermined target safe life index. K Indicates the lifetime dispersion factor. N f Indicates the predetermined target safe life index. a Indicates the stress coefficient. p This indicates the fatigue characteristic index.
[0048] In this step, steps S21-S22 are used to specifically explain the number of test cycles required to verify the turbine disk-baffle assembly to the predetermined target safe life index in the embodiments of the present invention.
[0049] Step S21: Determine the target safe life index.
[0050] Based on design analysis and actual verification requirements, the target safe life indexes that need to be verified for the turbine disk and baffle are determined. In this embodiment of the invention, the target safe life index stage can be adaptively adjusted according to actual tests. This invention describes the life verification method of turbine rotor timing coordination through three stages of target safe life indexes.
[0051] The predetermined target safe life indicators include: the first target safe life indicator. Second target: safe life index and the third target safe life index .
[0052] Step S22: Determine the number of experimental cycles for each stage. In this step, the lifetime dispersion coefficient K and the target safe lifetime index are combined. ( i =1, 2, 3 etc.), and the stress coefficients in formulas (1), (4), and (6) are used to determine the required number of test cycles for the turbine disk-baffle assembly. , and The calculation method is as follows: (7) (8) (9) In equations (7)-(9), This indicates that the turbine disk has been verified to the corresponding number. i The number of test cycles required to achieve the target safe life index; This indicates that the first baffle 3 has been verified to the corresponding... i The number of test cycles required to achieve the target safe life index; This indicates that the second baffle 4 has been verified to the corresponding... i The number of test cycles required to achieve the target safe life index; This indicates the turbine disk and the first baffle 3 and the second baffle 4. i Target safe life index, times; , , This indicates the stress coefficient of the key areas of the turbine disk, the first baffle 3, and the second baffle 4 under test conditions; p The fatigue characteristic index is mainly determined by the fatigue characteristics of the turbine disk material; K represents the life dispersion coefficient, a constant related to the number of test pieces. For example, when there is one test piece, K=4.
[0053] According to the above formula, the turbine disk (as the test specimen) was verified to the [number missing].i Safe life index The required number of test cycles is The first piece, the first baffle 3 (as the test piece), was verified to the first... i Safe life index The required number of test cycles is The first piece, the second baffle 4 (as the test piece), was verified to the first... i Safe life index The required number of test cycles is .
[0054] Step S3: Determine the replacement and reassembly time points for the baffle assembly based on the number of test cycles.
[0055] Specifically, determining the timing of the replacement and reinstallation of the baffle assembly includes: Based on the difference in the number of test cycles required for the baffle assembly and turbine disk to achieve their respective verification targets, the timing for replacing and reinstalling the baffle assembly is determined.
[0056] In this step, when it is necessary to verify multiple predetermined target safety life indicators, the time nodes for replacing and reinstalling the baffle assembly are determined as follows: Set multiple predetermined target safety life indicators for the turbine disk-baffle assembly to be verified, including previous target safety life indicators and subsequent target safety life indicators; Calculate the number of test cycles required to verify the turbine disk and baffle assembly to each predetermined target safety life index; When the next target safety life index is verified, the replacement and reinstallation time nodes of the baffle assembly are determined based on the number of test cycles required to verify the baffle assembly to the next target safety life index, the number of test cycles required to verify the baffle assembly to the previous target safety life index, and the number of test cycles required to verify the turbine disk to the previous target safety life index. According to the replacement and reinstallation time nodes, a multi-stage time-series coordinated life test including the replacement of the baffle assembly is performed.
[0057] In this step, steps S31-S33 are used to specifically explain the determination of the time nodes for replacing and reinstalling the baffle assembly in the embodiments of the present invention.
[0058] Step S31: Develop replacement and reinstallation strategies for each stage.
[0059] Under normal circumstances, the first baffle 3 and the second baffle 4 are in the over-test state, and some parts of the turbine disk are in the over-test state while others are in the under-test state. Therefore, the baffle reaches the required number of test cycles before the turbine disk, so the baffle needs to be replaced in advance. Based on the number of test cycles corresponding to the specified target safe life of the turbine disk and the first baffle 3 and the second baffle 4, the replacement and reinstallation nodes of the first baffle 3 and the second baffle 4 should be planned.
[0060] Specifically, assuming > > The replacement and reinstallation timelines for the first baffle 3 and the second baffle 4 are shown in Table 1.
[0061] Table 1. Calculation of the number of replacement and reassembly cycles for the first baffle 3 and the second baffle 4.
[0062] For example, the stress coefficients at the tenon, wheel center, and eccentric hole of a gas turbine disk are 1.045, 1.012, and 0.996, respectively, and the stress coefficients at the first baffle 3 and the second baffle 4 are 1.113 and 1.095, respectively; the safe service life of the gas turbine disk and the first baffle 3 and the second baffle 4 that need to be verified step by step are 6000, 8000, and 10000 cycles, respectively; and there is only one test piece (turbine disk and the first baffle 3 and the second baffle 4), so the service life dispersion coefficient K=4.
[0063] Table 2. Number of test cycles required to verify the specified target safe life index.
[0064] In Table 2, the stress coefficients of the turbine disk and the baffle are assumed. It is assumed that the fatigue characteristic index of a certain material is p=5. In actual application, targeted adjustments can be made for specific tests.
[0065] Table 3. Calculation of the number of nodes for the replacement and reassembly cycle of the first baffle 3 and the second baffle 4 in the first piece.
[0066] In Table 3, the stress coefficients of the turbine disk and baffle are assumed. It is assumed that the fatigue characteristic index of a certain material is p=5. The data marked with bold and * in the table indicate that the machine should be stopped and decomposed for inspection at the corresponding number of test cycles. In this embodiment of the invention, in order to save time, if necessary, similar data can be combined for inspection by taking the larger number of cycles.
[0067] Step S32: Evaluate the low-cycle fatigue life of the baffle.
[0068] Based on the above test conditions, the equivalent stress of the key parts of the first baffle 3 and the second baffle 4 is obtained based on formula (3). Combined with the fatigue performance data of the baffle material (such as SN curve or ε-N curve, etc.), the low cycle fatigue life of the key parts of the baffle under the test conditions is calculated, and the fatigue life of the first baffle (test piece) and the replacement baffle (accompanying test piece) is evaluated to see if they meet the test requirements.
[0069] Step S33: Prepare turbine disk and baffle test specimens.
[0070] According to the above test plan, the required number of test pieces is determined, one turbine disk test piece is prepared, and at least two sets (preferably three sets) of identical baffles that meet the drawing requirements (first baffle 3, second baffle 4), which are marked as the 1st piece, the 2nd piece, the 3rd piece, etc.
[0071] Step S4: Perform a sequential life test, including component replacement, on the turbine disk-baffle assembly according to the replacement and reinstallation time points.
[0072] Specifically, the sequential lifetime test includes: When the baffle assembly reaches the number of test cycles required to verify the target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the target safe life index of the baffle assembly is verified. Install the new baffle, pause the test when the turbine disk reaches the number of test cycles required to verify the target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the target safe life index of the turbine disk.
[0073] In this step, when it is necessary to verify multiple predetermined target safety life indicators, the multi-stage time-series coordinated life test includes: When the baffle assembly reaches the number of test cycles required for the previous verification target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the previous target safe life index of the baffle assembly is verified. Install a new baffle, pause the test when the turbine disk reaches the number of test cycles required for the previous verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the previous target safe life index of the turbine disk. Reassemble the baffle assembly, pause the test when the baffle assembly reaches the number of test cycles required for the next verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the safety life index of the baffle assembly for the next target. The new baffle is installed, and the test is paused when the turbine disk reaches the number of test cycles required for the next verification target. The turbine disk-baffle assembly is disassembled for non-destructive testing to verify the turbine disk's next target safe life index.
[0074] The following provides a detailed explanation of the multi-stage time-series co-living test process, in conjunction with Table 1: Step S41: Conduct fatigue tests in stages Assemble the turbine disk with the first baffle 3 and the second baffle 4. Apply a preset load spectrum to the test apparatus and run it until the number of cycles reaches the test cycle number specified in Table 1. Stop the machine and disassemble it. Perform comprehensive non-destructive testing on the turbine disk or the first baffle 3 and the second baffle 4 (such as fluorescence penetrant testing, ultrasonic testing, and dimensional measurement; the specific process of conducting fatigue testing in stages is described below). Step S411: The first piece, first baffle 3 (as the test piece), is tested until... The first baffle 3 was replaced with the second baffle 3 (as a test specimen), and the first baffle 4 (as the test specimen) was tested until... The first second baffle 4 was replaced with the second second baffle 4 (as a test piece). The turbine disk, first baffle 3, and second baffle 4 were tested until... At this point, the second baffle plate 3 and the second baffle plate 4 are removed. At this time, the turbine disk, the first baffle plate 3, and the first baffle plate 4 have all completed the first safe life index. Verification; depending on the actual verification needs, the first baffle 3 and the second baffle 4 of the first piece may be reinstalled as appropriate.
[0075] Step S412: The first piece, first baffle 3 (as the test piece), is tested until... - + The first baffle 3 is replaced by the second or third baffle 3 (as a test specimen), and the second baffle 4 of the first specimen (as the test specimen) is tested until... - + The first second baffle 4 is replaced with a second or third second baffle 4 (as a test piece). The turbine disk, first baffle 3, and second baffle 4 are tested until... At this time, the second or third first baffle 3 and second baffle 4 are removed. At this point, the turbine disk, the first first baffle 3, and the first second baffle 4 have all completed the second safe life index. Verification; depending on the actual verification needs, the first baffle 3 and the second baffle 4 of the first piece may be reinstalled as appropriate.
[0076] Step S413: The first piece, first baffle 3 (as the test piece), is tested until... - + The first baffle 3 is replaced by the third or fourth baffle 3 (as a test specimen), and the second baffle 4 of the first specimen (as the test specimen) is tested until... - + The first second baffle 4 is replaced with the third or fourth second baffle 4 (as a test piece). The turbine disk, first baffle 3, and second baffle 4 are tested until... At this time, the third or fourth first baffle 3 and second baffle 4 are removed. At this point, the turbine disk, the first first baffle 3, and the first second baffle 4 have all completed the third safe life index. Verification; depending on the actual verification needs, the first baffle 3 and the second baffle 4 of the first piece may be reinstalled as appropriate.
[0077] Step S414: By analogy, verify the first, second, and third target safe lifespans of the turbine disk, the first baffle 3, and the second baffle 4 step by step.
[0078] Step S5: After completing the sequential life test, determine whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
[0079] Step S51: Data Analysis and Model Revision The method described in this invention is a phased, time-sequential, and feedback-correctable verification process. If the inspection results match the expectations (no cracks in the baffle or only acceptable initial damage, and the turbine disk is intact), it proves that the number of test cycles is valid and meets the corresponding target safe life verification requirements. If there are deviations, the low-cycle fatigue life model is corrected using the inspection results, providing more accurate predictions for subsequent stages.
[0080] In this embodiment of the invention, the low-cycle fatigue life model is used for three-dimensional stress analysis and low-cycle fatigue life calculation of the turbine disk-baffle assembly in step S11, to identify life-shortcomings on the turbine disk and baffle assembly, and to define these life-shortcomings as test assessment areas; in this embodiment of the invention, the low-cycle fatigue life is calculated based on the stress calculation results of key parts of the turbine disk or baffle, combined with the fatigue performance data of the baffle material (such as SN curves or ε-N curves).
[0081] Optionally, in this embodiment of the invention, the low-cycle fatigue life model is used in step S32 to evaluate whether the fatigue life of the first baffle (test piece) and the replacement baffle (accompanying test piece) meets the test requirements.
[0082] Appropriately correct the stress in key parts of the turbine disk or baffle, for example, by considering a correction factor, and incorporate the corrected stress into the fatigue performance data of the material (such as SN curves or ε-N curves) so that the calculated life and test life results of the turbine disk or baffle are consistent.
[0083] Specifically, the verification result determination also includes: After completing the sequential life test, it is necessary to verify the actual safe life of the turbine disk-baffle assembly; Reassemble the baffle assembly and continue testing with the turbine disk until the full life test cycle number is reached; The test was paused when the turbine disk-baffle assembly reached the full life test cycle number to verify the actual life of the turbine disk-baffle assembly.
[0084] Step S52: Decision Analysis Path 1 (Verification Completed): If the analysis concludes that the turbine disk and baffle have been verified up to the [number]th [stage]... i Target safety life index If sufficient reliability and safety margin have been demonstrated and the verification objectives have been achieved, then the experiment is successfully completed.
[0085] Path Two (Continue Verification): If verification of the turbine disk and baffle to their full lifespan is required... , will have been used separately Second-rate, After the second cycle, and upon inspection confirming that the first baffle 3 and the second baffle 4 are intact, they are reinstalled on the turbine disk, and the test continues until the total number of cycles reaches [a certain number]. This action aims to verify the actual lifespan of the turbine disk and the first baffle 3 and the second baffle 4.
[0086] The present invention also describes the specific process of the turbine rotor timing-coordinated life verification method through a specific embodiment. Figure 5 A schematic diagram of the specific process of the turbine rotor timing-coordinated life verification method in an embodiment of the present invention is shown; Figure 5 The process begins by calculating the equivalent load and stress coefficient of the turbine disk-baffle assembly test to determine the target safe life and test cycle number planning. The first stage involves assembling the first baffle and turbine disk, testing until a specified test cycle number N1, then stopping the turbine, disassembling and inspecting, and performing non-destructive testing on the turbine disk and baffle to verify the first target safe life index of the baffle. The second new baffle is then assembled and tested along with the turbine disk until a specified test cycle number N2, and the turbine disk undergoes non-destructive testing to verify the first target safe life index of the turbine disk. The second stage involves reassembling the first baffle and continuing the test along with the turbine disk. Upon reaching a specified test cycle number N3, the turbine is shut down for disassembly and inspection. Non-destructive testing is performed on the turbine disk and baffle to verify the second target safe life index of the baffle. A second or third new baffle is then installed, and the turbine disk is tested until the specified test cycle number N4. The turbine disk is then subjected to non-destructive testing to verify its second target safe life index. A decision is made to determine whether the turbine disk and baffle have been sufficiently verified. If so, the test is successful. If verification to the actual safe life of the turbine disk and baffle is required, the third stage is executed: the first baffle is reinstalled, and the turbine disk test continues until the specified test cycle number N. total Non-destructive testing was performed on the turbine disk and baffle to verify their actual lifespan.
[0087] The proposed method for verifying the time-sequential coordinated lifespan of multiple components of a turbine rotor based on the separation principle has been shown through simulation analysis to meet experimental requirements. It can be applied in the development of related aero-engines and can be used to conduct coordinated lifespan tests on turbine rotor components. Both theoretical simulation and principle experiments have confirmed that the method of this invention is correct in principle, logically rigorous, and operationally feasible, effectively solving the aforementioned technical problems and laying a solid and reliable foundation for full-scale, full-parameter engineering applications.
[0088] This invention also provides a turbine rotor timing-coordinated life testing system. Figure 6 A schematic diagram of the turbine rotor timing-coordinated life verification system according to an embodiment of the present invention is shown. Figure 6 The system includes a coefficient determination module, a cycle number determination module, a time determination module, an experiment module, and a verification module. The coefficient determination module is configured to determine the stress coefficient of the turbine disk-baffle assembly pre-tested part under the upper limit speed of the fatigue test; The cycle number determination module is configured to determine the number of test cycles required to verify the turbine disk-baffle assembly to a predetermined target safe life index based on the stress coefficient. The time determination module is configured to determine the replacement and reassembly time points of the baffle assembly based on the number of test cycles; The test module is configured to perform a sequential life test, including component replacement, on the turbine disk-baffle assembly according to the replacement and reassembly time points; The verification module is configured to determine, after the sequential life test is completed, whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
[0089] This invention also provides a computer storage medium storing one or more instructions, which, when executed by one or more computers, cause the one or more computers to implement the turbine rotor timing-coordinated life test method of this invention.
[0090] The computer-readable storage medium stores a computer program that, when executed by a processor, implements the steps of the turbine rotor timing-coordinated life test method. Specifically, the computer-readable storage medium includes, but is not limited to, volatile memory and / or non-volatile memory. The volatile memory may include random access memory (RAM) and / or cache memory, etc. The non-volatile memory may include read-only memory (ROM), hard disk, flash memory, optical disk, magnetic disk, etc.
[0091] This invention discloses a method, system, and storage medium for verifying the time-series coordinated lifespan of a turbine rotor. It proposes a method for verifying the time-series coordinated lifespan of multiple components of a turbine rotor based on the separation principle. By employing multiple sets of baffle test specimens, alternately used as test specimens or auxiliary test specimens, the time-series coordinated lifespan verification of multiple components of a gas turbine rotor is achieved. Using the test scheme of this invention, premature failure of the baffle test specimens due to over-testing can be effectively avoided, effectively solving the problem of coordinated verification of the turbine disk-baffle assembly.
[0092] This invention decomposes the turbine rotor system into "long-life turbine disk components" and "short-life replaceable components such as baffles" for time-sequential verification, breaking the limitation of traditional overall testing where the system life is "vetoed" by the weakest component. It can independently verify the actual life limit of the turbine disk, avoiding the obscuring of the turbine disk's true load-bearing potential due to premature failure of auxiliary components such as baffles. The accurate life data obtained through layered verification can provide direct basis for lightweight design and performance improvement of core components such as turbine disks, avoiding weight and efficiency losses caused by overly conservative design.
[0093] This invention, through its replaceable design, allows a single turbine disk specimen to be used with multiple sets of baffles to complete multiple life cycle verifications. It transforms the overall test into a serialized verification that can be evaluated in stages and adjusted midway. Even if the verification of a certain baffle fails, it will not affect other components and subsequent verifications, greatly reducing the risk of global loss caused by single-point failure, significantly reducing test costs, and improving specimen utilization.
[0094] This invention fully verifies the long lifespan of the turbine disk and the multiple life cycles of the baffle through time-series life tests. The verification is complete and the conclusions are reliable. It fully explores the design potential and provides key data support that was previously unavailable for the development of engine maintenance programs based on actual damage data.
[0095] This invention can obtain continuous damage accumulation, crack initiation and propagation data throughout the entire life cycle by actively pausing the test, disassembling and inspecting, and replacing components at multiple preset life nodes. Through time-series collaborative verification, it can systematically obtain the interaction data between the turbine disk and the baffle at different stages.
[0096] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A method for verifying the time-series coordinated lifespan of a turbine rotor, characterized in that, The method includes: Determine the stress coefficient of the pre-tested part of the turbine disk-baffle assembly under the upper limit speed condition of fatigue test; The number of test cycles required to verify the turbine disk-baffle assembly to the predetermined target safe life index is determined based on the stress coefficient. The timing of baffle assembly replacement and reassembly is determined based on the number of test cycles. A sequential life test, including component replacement, is performed on the turbine disk-baffle assembly according to the replacement and reassembly time points; After completing the sequential life test, it is determined whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
2. The turbine rotor timing-coordinated life verification method according to claim 1, characterized in that, The determination of the stress coefficient of the pre-tested part of the turbine disk-baffle assembly includes: The equivalent stress of the pre-tested part under the upper limit speed of the fatigue test was obtained by finite element analysis. Based on the equivalent stress and material property data of the turbine disk-baffle assembly, the stress coefficient is calculated, which characterizes the fatigue damage rate of the pre-tested part under test conditions.
3. The turbine rotor timing-coordinated life verification method according to claim 1 or 2, characterized in that, The formula for calculating the number of test cycles is: in, N i This indicates the number of test cycles required for the turbine disk-baffle assembly to be verified to the predetermined target safe life index. K Indicates the lifetime dispersion factor. N f Indicates the predetermined target safe life index. a Indicates the stress coefficient. p This indicates the fatigue characteristic index.
4. The turbine rotor timing-coordinated life verification method according to claim 1 or 2, characterized in that, The determination of the timing for the replacement and reinstallation of the baffle assembly includes: Based on the difference in the number of test cycles required for the baffle assembly and turbine disk to achieve their respective verification targets, the timing for replacing and reinstalling the baffle assembly is determined.
5. The turbine rotor timing-coordinated life verification method according to claim 4, characterized in that, The sequential lifetime test includes: When the baffle assembly reaches the number of test cycles required to verify the target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the target safe life index of the baffle assembly is verified. Install the new baffle, pause the test when the turbine disk reaches the number of test cycles required to verify the target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the target safe life index of the turbine disk.
6. The turbine rotor timing-coordinated life verification method according to claim 1 or 2, characterized in that, The determination of the timing for the replacement and reinstallation of the baffle assembly includes: Set multiple predetermined target safety life indicators for the turbine disk-baffle assembly to be verified, including previous target safety life indicators and subsequent target safety life indicators; Calculate the number of test cycles required to verify the turbine disk and baffle assembly to each predetermined target safety life index; When the next target safety life index is verified, the replacement and reinstallation time nodes of the baffle assembly are determined based on the number of test cycles required to verify the baffle assembly to the next target safety life index, the number of test cycles required to verify the baffle assembly to the previous target safety life index, and the number of test cycles required to verify the turbine disk to the previous target safety life index. According to the replacement and reinstallation time nodes, a multi-stage time-series coordinated life test including the replacement of the baffle assembly is performed.
7. The turbine rotor timing-coordinated life verification method according to claim 6, characterized in that, The multi-stage time-series co-living test includes: When the baffle assembly reaches the number of test cycles required for the previous verification target, the test is paused, the turbine disk-baffle assembly is disassembled for non-destructive testing, and the previous target safe life index of the baffle assembly is verified. Install a new baffle, pause the test when the turbine disk reaches the number of test cycles required for the previous verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the previous target safe life index of the turbine disk. Reassemble the baffle assembly, pause the test when the baffle assembly reaches the number of test cycles required for the next verification target, disassemble the turbine disk-baffle assembly for non-destructive testing, and verify the safety life index of the baffle assembly for the next target. The new baffle is installed, and the test is paused when the turbine disk reaches the number of test cycles required for the next verification target. The turbine disk-baffle assembly is disassembled for non-destructive testing to verify the turbine disk's next target safe life index.
8. The turbine rotor timing-coordinated life verification method according to claim 7, characterized in that, The verification result determination also includes: After completing the sequential life test, if it is necessary to verify the actual safe life of the turbine disk-baffle assembly, the baffle assembly is reinstalled and the test continues with the turbine disk until the full life test cycle number is reached. The test was paused when the turbine disk-baffle assembly reached the full life test cycle number to verify the actual life of the turbine disk-baffle assembly.
9. A turbine rotor time-series coordinated life testing system, characterized in that, The system includes a coefficient determination module, a cycle number determination module, a time determination module, an experimentation module, and a verification module. The coefficient determination module is configured to determine the stress coefficient of the turbine disk-baffle assembly pre-tested part under the upper limit speed of the fatigue test; The cycle number determination module is configured to determine the number of test cycles required to verify the turbine disk-baffle assembly to a predetermined target safe life index based on the stress coefficient. The time determination module is configured to determine the replacement and reassembly time points of the baffle assembly based on the number of test cycles; The test module is configured to perform a sequential life test, including component replacement, on the turbine disk-baffle assembly according to the replacement and reassembly time points; The verification module is configured to determine, after the sequential life test is completed, whether the turbine disk-baffle assembly has reached the verification target of the predetermined target safe life index.
10. A computer storage medium, characterized in that, The computer storage medium stores one or more instructions that, when executed by one or more computers, cause the one or more computers to perform the method of any one of claims 1-8.