CN112632826B - Method for obtaining welding mode of blade disc shaft neck of aero-engine - Google Patents
Method for obtaining welding mode of blade disc shaft neck of aero-engine Download PDFInfo
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Abstract
The invention discloses a method for obtaining a welding mode of a blade disc shaft neck of an aero-engine, and belongs to the field of welding of the blade disc shaft neck of the aero-engine. The blade disc and journal welding calculation method of the aero-engine based on numerical simulation has the advantages that the three-dimensional solid model is established in a targeted mode according to the configurations of the blade disc and the journal, the electron beam welding heat source model is selected, waste of a large number of test workpieces is avoided by utilizing the numerical simulation method, meanwhile, the welding simulation precision is improved, and welding temperature field distribution and stress field distribution with higher quality are obtained.
Description
Technical Field
The invention belongs to the field of welding of a blade disc journal part of an aeroengine.
Background
In the traditional verification test for welding the blade disc and the shaft neck of the aero-engine, various welding modes and welding parameters of different types need to be tested manually to obtain high-performance welding quality. However, this situation is dependent on worker experience, resulting in long test times, waste of material resources, and difficulty in obtaining a complex and diverse distribution of stress and temperature fields of the device after soldering.
But through a numerical simulation method, computer software can be directly utilized, the residual stress and temperature field distribution of welding can be predicted and analyzed by adopting a finite element method, and a small amount of tests are assisted for verification and adjustment, so that the test period can be greatly shortened, the material utilization rate is increased, and the production cost is saved.
Disclosure of Invention
The invention provides a method for acquiring a welding mode of a blisk shaft neck of an aeroengine, aiming at the condition that the distribution verification of residual stress and temperature field after the blisk shaft neck in the aeroengine is welded is difficult.
The technical scheme of the invention is a method for obtaining a welding mode of a blade disc shaft neck of an aeroengine, which comprises the following steps:
step 1: determining the configuration of a blade disc and a shaft neck in the aircraft engine, and establishing a three-dimensional solid model of the blade disc and the shaft neck according to the determined configuration;
step 2: carrying out finite element meshing on the three-dimensional solid model of the blade disc and the shaft neck in the step 1 to form a plurality of mesh units of the solid model of the blade disc and the shaft neck;
step 2.1: geometrically cleaning the three-dimensional solid model in the step 1, firstly deleting free nodes in the model, then fusing coincident nodes and coincident units, and repeatedly confirming;
step 2.2: carrying out grid division on a hexahedron in a three-dimensional solid model selection area, dividing a near-weld area and a near-weld area into dense grids, and dividing other areas into sparse grids;
step 2.3: performing quality inspection on the divided grids;
step 2.4: detecting the unit boundary of the division result, detecting whether cracks appear or not, and filling if cracks appear;
and step 3: grouping the three-dimensional solid models of the grids divided in the step 2, and determining a welding seam, a welding reference line, a welding starting unit, a welding starting point, a welding end point, a clamping condition, a load and a heat conduction surface;
and 4, step 4: performing heat source checking on the blade disc and the shaft neck;
step 4.1: the following double-ellipsoid model is adopted as a heat source model for welding;
the front part and the rear part of the double-ellipsoid heat source model adopt different expressions, and the heat sources are distributed in the front half part of the ellipsoid as follows:
the expression of the heat source distribution in the ellipsoid of the second half part is as follows:
wherein Q = eta UI, eta is heat source efficiency, U is welding voltage, and I is welding current; a, b, c are ellipsoidal parameters, f 1 ，f 2 Is a function of the heat distribution of front and rear ellipsoids, and 1 +f 2 ＝2；
step 4.2: the blade disc and the shaft neck are made of TC17 titanium alloy materials;
and 5: determining welding current, voltage and welding speed;
step 6: calculating the heat input q of welding according to the electron beam welding heat source model selected in the steps 4 and 5 and the physical parameters of the materials;
where eta is the power efficient utilization coefficient, I n For welding current, U n Is the welding voltage, v is the welding speed;
and 7: welding Heat input obtained according to step 6
And heat source generation amount phi V Calculating the temperature peak point in the temperature distribution area during welding to ensure that the peak point is kept in a reasonable range, if the peak point is not in the reasonable range, adjusting parameters in the step 6, and calculating the temperature peak point according to the following formula:
wherein ρ is the material density, T is the temperature, determined in step 4, C L Is the specific heat capacity coefficient, K x ，K y ，K z For the thermal conductivity in the x, y, z directions, the conductivity is set to be isotropic, so that there are:
K x (T)＝K y (T)＝K z (T)；
and 8: determining the boundary of the blade disc and the shaft neck, and calculating the longitudinal shrinkage delta L of the welding seam according to the set mechanical performance parameters as follows:
wherein, ε = α [ T ] 1 -T 0 ]Where α is a temperature-independent metal property parameter, T 1 Is the peak temperature, T 0 As initial temperature, n is the number of multi-layer and multi-pass welding layers, K 1 The coefficient related to the welding method, the coefficient of thermal expansion of materials and multi-layer and multi-pass welding is determined according to actual conditions, F H The energy action area of the welding line is shown, L represents the length of a welding seam, and F represents the sectional area of a workpiece;
a transverse shrinkage of
Wherein beta is a fixed rigidity index, q is welding line energy, and sigma represents transverse residual stress, so that the longitudinal shrinkage and the transverse shrinkage of the welding seam are ensured to be in a reasonable range, and if the longitudinal shrinkage and the transverse shrinkage are not in the reasonable range, the parameters in the step 6 are used for adjusting.
The blade disc and journal welding calculation method based on numerical simulation has the advantages that the three-dimensional solid model is established in a targeted mode according to the configuration of the blade disc and the journal, the electron beam welding heat source model is selected, waste of a large number of test workpieces is avoided by utilizing the numerical simulation method, meanwhile, the welding simulation precision is improved, and welding temperature field distribution and stress field distribution with higher quality are obtained.
Drawings
FIG. 1 is a route diagram of a blade disc and journal welding simulation method of an aircraft engine based on numerical simulation;
FIG. 2 is a three-dimensional solid model of a blisk and a journal;
FIG. 3 is a blisk and journal grid division;
FIG. 4 is a nodal clean-up of the blisk and journal;
FIG. 5 is a weld line arrangement of the blisk and journal;
FIG. 6 is a heat affected zone setup of a blisk and journal;
FIG. 7 illustrates a rigid clamping condition of the blisk and journal;
FIG. 8 illustrates a symmetric clamping condition of the blisk and journal;
FIG. 9 is a temperature field distribution for electron beam welding of the blisk to the journal;
FIG. 10 is a temperature profile of the blisk and journal electron beam welding;
FIG. 11 is a graph of change in stress displacement for blisk and journal electron beam welding.
The specific implementation mode is as follows:
the invention discloses a numerical simulation-based blade disc and journal welding simulation method for an aircraft engine, which is further described in the following by combining the accompanying drawings, wherein a specific implementation route is shown in fig. 1.
Step 1: selecting a standard configuration of a blade disc and a shaft neck in the aircraft engine, and establishing a three-dimensional solid model of the blade disc and the shaft neck according to the standard configuration, as shown in FIG. 2;
step 2: carrying out finite element meshing on the three-dimensional solid model of the blade disc and the shaft neck in the step 1 to form a plurality of mesh units of the solid model of the blade disc and the shaft neck so as to carry out finite element analysis after welding as shown in figure 3;
step 2.1: geometrically cleaning the three-dimensional solid model in the step 1, firstly deleting free nodes in the model, then fusing coincident nodes and coincident units, and repeatedly confirming, as shown in FIG. 4;
step 2.2: carrying out grid division on a hexahedron in a three-dimensional solid model selection area, dividing a near-weld area and a near-weld area into dense grids, and dividing other areas into sparse grids;
step 2.3: performing quality inspection on the divided grids;
step 2.4: detecting the unit boundary of the division result, and detecting whether cracks appear;
and step 3: grouping the three-dimensional solid models divided into grids in the step 2, and determining a welding seam, a welding reference line, a welding starting unit, a welding starting point, a welding end point, a clamping condition, a load and a heat conduction surface;
step 3.1: drawing a welding track line and a welding reference line, and determining a welding starting unit and a welding starting point, as shown in FIG. 5;
step 3.2: defining a load set, and defining a welding seam and adjacent units thereof as a heat affected zone;
step 3.3: determining clamping conditions, selecting rigid clamping in the X direction and symmetrical clamping in the Z direction, as shown in FIGS. 7 and 8;
step 3.4: defining a heat transfer surface;
and 4, step 4: performing heat source checking on the blade disc and the shaft neck;
step 4.1: selecting a double-ellipsoid model as a heat source model for welding simulation according to models of a leaf disc and a shaft neck and an electron beam welding mode;
the front part and the rear part of the double-ellipsoid heat source model adopt different expressions, and the heat sources are distributed in the front half part of the ellipsoid as follows:
the expression of the heat source distribution in the ellipsoid of the second half part is as follows:
wherein Q = η UI, η is heat source efficiency, U is welding voltage with unit of V, I is welding current with unit of A; a, b, c are ellipsoidal parameters, f 1 ，f 2 Is a function of the heat distribution of front and rear ellipsoids, and 1 +f 2 ＝2；
and 4.2: the blade disc and the shaft neck are made of titanium alloy materials, and various material parameters are determined;
and 5: various process parameter settings are carried out on the blisk and the shaft neck in welding numerical simulation software, and details are shown in table 1.
Table 1 process parameter settings
| Welding speed | 6mm/sec |
| Total length of welding | 769mm |
| Width of welding (front) | 7mm |
| Width of welding (bottom) | 2mm |
| Depth of welding | 15.025mm |
| Unit energy ratio | 500J/mm |
Step 6: generating a heat input interval and a temperature distribution area of electron beam welding according to the electron beam welding heat source model selected in the steps 4 and 5 and the physical parameters of the materials, wherein the simulation result of the temperature field is shown in figure 9;
and 7: according to the welding heat input interval and the temperature distribution region determined in the step 6, the temperature length distribution guidelines of the blade disc and the shaft neck are carried out to determine each temperature peak point in the temperature distribution region, the simulation result is shown in fig. 10, the temperature peak point reaches 600 kelvin, and then the temperature is reduced to be below 100 ℃ in 3 minutes;
and 8: and applying boundary conditions to the blade disc and the shaft neck, and performing dynamic stress result analysis in welding numerical simulation software according to various set mechanical performance parameters, wherein the mechanical analysis stress displacement change result is shown in figure 11, and the analysis result shows that the mechanical stress displacement change in three directions is within 0.3 mm.
Claims (2)
1. A method of obtaining a weld pattern for a blisk journal of an aircraft engine, the method comprising the steps of:
step 1: determining the configuration of a blade disc and a shaft neck in the aircraft engine, and establishing a three-dimensional solid model of the blade disc and the shaft neck according to the determined configuration;
and 2, step: carrying out finite element meshing on the three-dimensional solid model of the blade disc and the shaft neck in the step 1 to form a plurality of mesh units of the solid model of the blade disc and the shaft neck;
and step 3: grouping the three-dimensional solid models divided into grids in the step 2, and determining a welding seam, a welding reference line, a welding starting unit, a welding starting point, a welding end point, a clamping condition, a load and a heat conduction surface;
and 4, step 4: performing heat source checking on the blade disc and the shaft neck;
step 4.1: the following double-ellipsoid model is adopted as a heat source model for welding;
wherein, the front and back parts of the double-ellipsoid heat source model adopt different expressions, and the heat source distribution in the front half part of ellipsoid is as follows:
the expression of the heat source distribution in the ellipsoid of the second half part is as follows:
wherein Q = η UI, η is heat source efficiency, U is welding voltage, and I is welding current; a, b, c are ellipsoidal parameters, f 1 ，f 2 Is a function of the heat distribution of front and rear ellipsoids, and 1 +f 2 ＝2；
step 4.2: the blade disc and the shaft neck are made of TC17 titanium alloy materials;
and 5: determining welding current, voltage and welding speed;
step 6: calculating the heat input q of welding according to the electron beam welding heat source model selected in the steps 4 and 5 and the physical parameters of the materials;
where eta is the power efficient utilization coefficient, I n For welding current, U n Is the welding voltage, v is the welding speed;
and 7: welding Heat input obtained according to step 6
And heat source generation amount phi V Calculating the temperature peak point in the temperature distribution area during welding to ensure that the peak point is kept in a reasonable range, if the peak point is not in the reasonable range, adjusting parameters in the step 6, and calculating the temperature peak point according to the following formula:
wherein ρ is the material density, T is the temperature, determined in step 4, C L Is the specific heat capacity coefficient, K x ，K y ，K z For the thermal conductivity in the x, y, z directions, the conductivity is set to be isotropic, so that there are:
K x (T)＝K y (T)＝K z (T)；
and 8: determining the boundary of the blade disc and the shaft neck, and calculating the longitudinal shrinkage delta L of the welding seam according to the set mechanical performance parameters as follows:
wherein, ε = α [ T ] 1 -T 0 ]Where α is a temperature-independent metal property parameter, T 1 Is the peak temperature, T 0 As initial temperature, n is the number of multi-layer and multi-pass welding layers, K 1 The coefficient related to the welding method, the coefficient of thermal expansion of materials and multi-layer and multi-pass welding is determined according to actual conditions, F H The energy action area of the welding line is shown, L represents the length of a welding seam, and F represents the sectional area of a workpiece;
a transverse shrinkage of
Wherein beta is a fixed rigidity index, q is welding line energy, and sigma represents transverse residual stress, so that the longitudinal shrinkage and the transverse shrinkage of the welding seam are ensured to be in a reasonable range, and if the longitudinal shrinkage and the transverse shrinkage are not in the reasonable range, the parameters in the step 6 are used for adjusting.
2. The method for obtaining the blade disc journal welding mode of the aircraft engine according to claim 1, wherein the specific method of the step 2 is as follows:
step 2.1: geometrically cleaning the three-dimensional solid model in the step 1, firstly deleting free nodes in the model, then fusing coincident nodes and coincident units, and repeatedly confirming;
step 2.2: carrying out grid division on a hexahedron in a three-dimensional solid model selection area, dividing a near-weld area and a near-weld area into dense grids, and dividing other areas into sparse grids;
step 2.3: performing quality inspection on the divided grids;
step 2.4: and detecting the unit boundary of the division result, detecting whether cracks appear, and filling if cracks appear.
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Non-Patent Citations (4)
| Title |
|---|
| Numerical simulation of weld tab length infulence on welding residual stress and distortion of aero-engine disk;Xue qiu ZHANG et al;《Frontiers of Materials Science in China》;20090603;306-309 * |
| 整体叶盘电子束焊接残余应力和变形的虚拟优化;陈绪辉;《中国优秀博硕士学位论文全文数据库(硕士)工程科技Ⅱ辑》;20111215;C031-135 * |
| 某风机焊接转子动特性分析;于宁等;《科学技术创新》;20200805(第22期);35-36 * |
| 线性摩擦焊接过程三维热力耦合有限元分析;杜随更等;《西北工业大学学报》;20020630(第02期);180-182 * |
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