汽轮机叶片精密模锻技术CAD与CAE研究
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摘要
汽轮机叶片是汽轮机的核心零部件，起能量转换的关键作用。由于使用环境和性能的要求，以及制造成本方面的考虑，越来越多的厂家采用了精锻的生产工艺。本文针对叶片精锻工艺设计的实际要求，在总结了工厂经验的基础上，以Unigraphics（NX）为开发平台，应用参数化的思想，对叶片精锻模具CAD二次开发做了系统的研究。另外，采用Msc.SuperForm软件，对叶片锻造过程进行了模拟优化。主要内容如下：
分析了叶片锻造模具设计中平衡角的确定方法；在工厂实际操作基础上，总结出四种精锻叶片型线修整方法及四种模锻叶片型线修整的方法，对叶根进行了分类，给出叶根设计计算的过程。
针对叶片锻件设计中的型线修整各种方法，在UG平台上应用UG的通用开发语言UG Open/GRIP，采用参数化的思想开发了型线修整GRIP程序。
应用用户自定义特征（UDF）的方法，结合草图、参数化及表达式技术，建立了叶根库；应用部件家族（Part family）及电子表格的技术，建立了模块库及常用零件库；应用API开发语言MenuScript，为系统编写了菜单。
以叶片成形作平面变形问题，利用商用有限元软件Msc.SuperForm对叶片成形作了有限元模拟，分析了能量预选对螺旋压力机精锻叶片的影响；采用不同形式的预成形毛坯，对预成形对叶片精密锻造的影响做了分析，得出不同形式坯料的成形规律，分析了各种形式坯料成形的优缺点；总结了叶片精锻成形的流动规律。
Turbine blades are core components in turbine, which play important roles in energy transformation. More and more manufacturer apply precision forging to the produce of blade, due to the special working environment and properties needed of blade, as well as the advantage of cost in precision forging compared with conventional forging. According to the needs of factory, applying parametric method, special development of CAD for the blade precision forging die is systematically studied on the basis of UG(NX) in this thesis after summing up the expertise of factory. The main content is as below:
The methods of definition the equilibrium angle in forging die design have been analyzed. Four sorts of airfoil section trimming methods of precision and average forging have been summed up on the basis of factory. The blade roots have been categorized and their design process were given.
According to the key difficult, section curve trimming, in forging design, a procedure was developed adopting developing language -UG Open/GRIP. This procedure can reduce the blade forging design period and bring convenience to the user.
Using UDF method and other technique of UG including sketcher, expression, a blade root warehouse was established. A die block warehouse and frequent using part warehouse was established as well applying Part family and Spreadsheet technique. System menus were developed by using MenuScript, a sort of API developing language.
Assuming the deformation of blade in forging was a plane deformation problem, FEM simulation was performed using commercially available FEM software package-Msc.SuperForm. Studies on the influence of energy of screw press on precision forging of blade. Analysis of different sort of billet’s merits and demerits in blade forming was performed and the forming rule was obtained.
分析了叶片锻造模具设计中平衡角的确定方法；在工厂实际操作基础上，总结出四种精锻叶片型线修整方法及四种模锻叶片型线修整的方法，对叶根进行了分类，给出叶根设计计算的过程。
针对叶片锻件设计中的型线修整各种方法，在UG平台上应用UG的通用开发语言UG Open/GRIP，采用参数化的思想开发了型线修整GRIP程序。
应用用户自定义特征（UDF）的方法，结合草图、参数化及表达式技术，建立了叶根库；应用部件家族（Part family）及电子表格的技术，建立了模块库及常用零件库；应用API开发语言MenuScript，为系统编写了菜单。
以叶片成形作平面变形问题，利用商用有限元软件Msc.SuperForm对叶片成形作了有限元模拟，分析了能量预选对螺旋压力机精锻叶片的影响；采用不同形式的预成形毛坯，对预成形对叶片精密锻造的影响做了分析，得出不同形式坯料的成形规律，分析了各种形式坯料成形的优缺点；总结了叶片精锻成形的流动规律。
Turbine blades are core components in turbine, which play important roles in energy transformation. More and more manufacturer apply precision forging to the produce of blade, due to the special working environment and properties needed of blade, as well as the advantage of cost in precision forging compared with conventional forging. According to the needs of factory, applying parametric method, special development of CAD for the blade precision forging die is systematically studied on the basis of UG(NX) in this thesis after summing up the expertise of factory. The main content is as below:
The methods of definition the equilibrium angle in forging die design have been analyzed. Four sorts of airfoil section trimming methods of precision and average forging have been summed up on the basis of factory. The blade roots have been categorized and their design process were given.
According to the key difficult, section curve trimming, in forging design, a procedure was developed adopting developing language -UG Open/GRIP. This procedure can reduce the blade forging design period and bring convenience to the user.
Using UDF method and other technique of UG including sketcher, expression, a blade root warehouse was established. A die block warehouse and frequent using part warehouse was established as well applying Part family and Spreadsheet technique. System menus were developed by using MenuScript, a sort of API developing language.
Assuming the deformation of blade in forging was a plane deformation problem, FEM simulation was performed using commercially available FEM software package-Msc.SuperForm. Studies on the influence of energy of screw press on precision forging of blade. Analysis of different sort of billet’s merits and demerits in blade forming was performed and the forming rule was obtained.
引文
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2 C. R. Boer, H. Rydstad, G. Schroder. Process Modeling of Metal Forming and Thermomechanical Treatment.Springe-Verlag,Berlin,1986:85-200
3 肖景容.精密模锻.北京:机械工业出版社,1985:24-80
4 吕炎.锻压成形理论与工艺.北京:机械工业出版社,1991:99-110
5黄春峰.1Cr17Ni2钢叶片热处理工艺优化.航空工艺技术,1992,(2):58-59
6 王乐安.航空工业中锻压技术及其发展.锻压技术,1994,(1):57-61
7 粟祜,许日泽,刘侠夫.叶片精锻. 北京:国防工业出版社,1984:11-38
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10 Iles D G. Forgings for Aircraft Engines. Metal Forming. 1970, 10:285-290
11 Voigtlander C, Gunther G. Isothermal Precision ForgingAero-engine Compressor Blades Made in Titanium Alloys. Metallurgy, 1983, 8:322-326
12 Akgerman N, Altan T. Application of CAD/CAM in Forging Turbine and Compressor Blades. Eng. Power Trans. ASME, 1976,4:290-296
13 王海荣.叶片锻造过程有限元分析及其CAD系统微机化.[西北工业大学硕士学位论文].1987:35-45
14 朱谨.叶片精锻工艺及模具设计CAD的过程.锻压技术,1992,(1):18-21
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..Swansea ,UK , Pineridge Press,1982:343-349
21 N.Rebelo,H.Rydstad,G.Schroder.Simulation of Material Flow in Closed-die Forging by Model Techniques and Rigid-plastic FEM.in:.F.T.and.Pittmann Num. Meth. Ind. Form Proc. Swansea, UK, Pineridge Press,1982:237-246
22 N.L.Dung and O.Mahrenholtz. Progress in the Analysis of Unsteady Metal-Forming Processes Using the FEM.in:J.F.T.and I.Pittman eds,,Num, Meth. Ind.Form .Proc.. Swansea, UK, Pineridge Press,1982:187-196
23 B.S.Kang,N.S.Kim,S.Kobayashi.Computer Aided Preform Design in Forging of an Airfoil Section Blade.Int.J.Mach.Tools Manufact..1990,30(1):43-52
24 H.Ou,C.G.Armstrong,M.A.Price.Die Shape Optimisation in Forging of Aerofiil Sections. J.Mat.Process.Technol,2003,133:21-27
25 H.Ou,R.Balendra.Die-elasticity for Precision Forging of Aerofoil Section Using Finite Element Simulation.J.Mat.Process.Technol,1998,76:56-61
26连建民.叶片精锻过程刚粘塑性有限元模拟.航空部第621研究所,1986.1:23-25
27 詹梅.面向带阻尼台叶片精锻过程的全三维有限元数值模拟.[西北工业大学博士学位论文].2000:8-10
28 刘郁丽.叶片精锻成形规律的三维有限元分析.[西北工业大学博士学位论文].2001:4-10
29 Zhen Wang,Kemin Xue,Yingwei Liu.Backward UBET Simulation of the Forging of a Blade. J.Mat.Process.Technol.1997,65:18-21
30 Mei Zhan,Liu Yuli,Yang He.Research on a New Remeshing Method for the 3D FEM Simulation of Blade Forging.J.Mat.Process.Technol.1999,94:231-234
31 Mei Zhan,Yuli Liu,He Yang.Influence of the Shape and Position of the Preform in the Precision Forgine of a Compressor Blade. J.Mat.Process.Technol.2002,120:80-83
32 米小珍.涡轮叶片平衡角的优化设计. 锻压技术,1998,1:54-56
33 米小珍,郑大梁,侯英伟.涡轮叶片锻造成形过程的计算机模拟.大连铁道学院学报,1998,19(4):83-86
34 Unigraphics．Brief introduction．EDS Unigraphics,1996:157-165
35 EDS Unigraphics Solution．Unigraphics Essential,1995:67-80
36 EDS Unigraphics Solution．Unigraphics Modeling,1995:131-149
37 EDS Unigraphics Solution．UG／OPEN API Reference,1995:463-486
38 EDS Unigraphics So1ution．Unigraphics Drafting,1995:163-180
39 EDS Unigraphics So1ution．Unigraphics Assemblies,1995:205-225
40 EDS Unigraphics solution．Unigraphics Mechanisms,1995:367-388
41李浩,谢庆生.基于特征的参数化造型的思想.CAD/CAM计算机辅助设计与制造,2000,5:31-34
42 孙家广,陈玉健.计算机辅助几何造型技术.北京:清华大学出版社,1990:56-59
43 王庆林.UG/Open GRIP实用编程基础.北京:清华大学出版社,2002:23-29
44 黄俊明,吴运明,詹永裕.UnigraphicsII模型设计.北京:中国铁道出版社,2001:111-200
45 Unigraphics Solutions Inc.UG知识熔接技术培训教程.北京:清华大学出版社,2003:169-199
46 董正卫,田中立,付宜利.UG/OPEN API编程基础.北京:清华大学出版社,2002:1-30
47 龚勉,唐海翔,赵波,等.UG CAD应用案例集(NX版).北京:清华大学出版社,2003:349-381
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63 L.B.Aksenov, N.R.Chitkata.Pressure and Deformation in the Plane Strain Pressing of Circular Section Bar to Form Turbine Blades.Int.J.Meth.Sci, 1975,17:681-691
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70 左旭.塑性成形三维数值模拟中模具几何描述技术.锻压技术,1997,6:59-61
2 C. R. Boer, H. Rydstad, G. Schroder. Process Modeling of Metal Forming and Thermomechanical Treatment.Springe-Verlag,Berlin,1986:85-200
3 肖景容.精密模锻.北京:机械工业出版社,1985:24-80
4 吕炎.锻压成形理论与工艺.北京:机械工业出版社,1991:99-110
5黄春峰.1Cr17Ni2钢叶片热处理工艺优化.航空工艺技术,1992,(2):58-59
6 王乐安.航空工业中锻压技术及其发展.锻压技术,1994,(1):57-61
7 粟祜,许日泽,刘侠夫.叶片精锻. 北京:国防工业出版社,1984:11-38
8 任仲贵.CAD/CAM原理.北京:清华大学出版社,1997:5-10
9 陆国栋,黄长林.CAD图形与支撑软件的开发现状及开发热点.计算机辅助设计和制造,1996,(4):23-27
10 Iles D G. Forgings for Aircraft Engines. Metal Forming. 1970, 10:285-290
11 Voigtlander C, Gunther G. Isothermal Precision ForgingAero-engine Compressor Blades Made in Titanium Alloys. Metallurgy, 1983, 8:322-326
12 Akgerman N, Altan T. Application of CAD/CAM in Forging Turbine and Compressor Blades. Eng. Power Trans. ASME, 1976,4:290-296
13 王海荣.叶片锻造过程有限元分析及其CAD系统微机化.[西北工业大学硕士学位论文].1987:35-45
14 朱谨.叶片精锻工艺及模具设计CAD的过程.锻压技术,1992,(1):18-21
15 赵遵成.基于UGII的叶片精锻模CAD系统研究.[西北工业大学硕士学位论文].2001:3-15
16 张世华,尹德捷.CAD应用中的问题之一——关于软件二次开发的研究.计算机辅助设计和制造,1996,(8):57-60
17 曾记荣.CAD在产品系列化设计中的应用.机械,1996,(4):17-18
18 张红桩.基于UG平台的轿车轮毂CAD/CAM一体化研究.[燕山大学硕士学位论文].1999:22-27
19 吴瑜.闭塞成形液压机本体CAD参数化设计研究.[燕山大学硕士学位论文].2002:3-8
20 Mark Shahaf,Michel Bercovier.Interactive Simulation of a Forging Process for Blades.in: J.F.T.and I. Pittman eds.Num .Meth .Ind .Form .Proc
..Swansea ,UK , Pineridge Press,1982:343-349
21 N.Rebelo,H.Rydstad,G.Schroder.Simulation of Material Flow in Closed-die Forging by Model Techniques and Rigid-plastic FEM.in:.F.T.and.Pittmann Num. Meth. Ind. Form Proc. Swansea, UK, Pineridge Press,1982:237-246
22 N.L.Dung and O.Mahrenholtz. Progress in the Analysis of Unsteady Metal-Forming Processes Using the FEM.in:J.F.T.and I.Pittman eds,,Num, Meth. Ind.Form .Proc.. Swansea, UK, Pineridge Press,1982:187-196
23 B.S.Kang,N.S.Kim,S.Kobayashi.Computer Aided Preform Design in Forging of an Airfoil Section Blade.Int.J.Mach.Tools Manufact..1990,30(1):43-52
24 H.Ou,C.G.Armstrong,M.A.Price.Die Shape Optimisation in Forging of Aerofiil Sections. J.Mat.Process.Technol,2003,133:21-27
25 H.Ou,R.Balendra.Die-elasticity for Precision Forging of Aerofoil Section Using Finite Element Simulation.J.Mat.Process.Technol,1998,76:56-61
26连建民.叶片精锻过程刚粘塑性有限元模拟.航空部第621研究所,1986.1:23-25
27 詹梅.面向带阻尼台叶片精锻过程的全三维有限元数值模拟.[西北工业大学博士学位论文].2000:8-10
28 刘郁丽.叶片精锻成形规律的三维有限元分析.[西北工业大学博士学位论文].2001:4-10
29 Zhen Wang,Kemin Xue,Yingwei Liu.Backward UBET Simulation of the Forging of a Blade. J.Mat.Process.Technol.1997,65:18-21
30 Mei Zhan,Liu Yuli,Yang He.Research on a New Remeshing Method for the 3D FEM Simulation of Blade Forging.J.Mat.Process.Technol.1999,94:231-234
31 Mei Zhan,Yuli Liu,He Yang.Influence of the Shape and Position of the Preform in the Precision Forgine of a Compressor Blade. J.Mat.Process.Technol.2002,120:80-83
32 米小珍.涡轮叶片平衡角的优化设计. 锻压技术,1998,1:54-56
33 米小珍,郑大梁,侯英伟.涡轮叶片锻造成形过程的计算机模拟.大连铁道学院学报,1998,19(4):83-86
34 Unigraphics．Brief introduction．EDS Unigraphics,1996:157-165
35 EDS Unigraphics Solution．Unigraphics Essential,1995:67-80
36 EDS Unigraphics Solution．Unigraphics Modeling,1995:131-149
37 EDS Unigraphics Solution．UG／OPEN API Reference,1995:463-486
38 EDS Unigraphics So1ution．Unigraphics Drafting,1995:163-180
39 EDS Unigraphics So1ution．Unigraphics Assemblies,1995:205-225
40 EDS Unigraphics solution．Unigraphics Mechanisms,1995:367-388
41李浩,谢庆生.基于特征的参数化造型的思想.CAD/CAM计算机辅助设计与制造,2000,5:31-34
42 孙家广,陈玉健.计算机辅助几何造型技术.北京:清华大学出版社,1990:56-59
43 王庆林.UG/Open GRIP实用编程基础.北京:清华大学出版社,2002:23-29
44 黄俊明,吴运明,詹永裕.UnigraphicsII模型设计.北京:中国铁道出版社,2001:111-200
45 Unigraphics Solutions Inc.UG知识熔接技术培训教程.北京:清华大学出版社,2003:169-199
46 董正卫,田中立,付宜利.UG/OPEN API编程基础.北京:清华大学出版社,2002:1-30
47 龚勉,唐海翔,赵波,等.UG CAD应用案例集(NX版).北京:清华大学出版社,2003:349-381
48 单德彬,吕炎,王真.金属体积成形过程三维刚塑性有限元模拟技术研究.塑性工程学报,1997,3:98-102
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