CN112651157A - Aviation thin-walled part plasma spraying deformation control method - Google Patents
Aviation thin-walled part plasma spraying deformation control method Download PDFInfo
- Publication number
- CN112651157A CN112651157A CN202011555697.0A CN202011555697A CN112651157A CN 112651157 A CN112651157 A CN 112651157A CN 202011555697 A CN202011555697 A CN 202011555697A CN 112651157 A CN112651157 A CN 112651157A
- Authority
- CN
- China
- Prior art keywords
- thin
- plasma spraying
- deformation
- wall part
- stress
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/25—Measuring force or stress, in general using wave or particle radiation, e.g. X-rays, microwaves, neutrons
- G01L1/255—Measuring force or stress, in general using wave or particle radiation, e.g. X-rays, microwaves, neutrons using acoustic waves, or acoustic emission
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0047—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes measuring forces due to residual stresses
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
-
- G—PHYSICS
- G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
- G16C—COMPUTATIONAL CHEMISTRY; CHEMOINFORMATICS; COMPUTATIONAL MATERIALS SCIENCE
- G16C60/00—Computational materials science, i.e. ICT specially adapted for investigating the physical or chemical properties of materials or phenomena associated with their design, synthesis, processing, characterisation or utilisation
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
Landscapes
- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Theoretical Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Geometry (AREA)
- Computer Hardware Design (AREA)
- Computing Systems (AREA)
- General Engineering & Computer Science (AREA)
- Evolutionary Computation (AREA)
- Bioinformatics & Computational Biology (AREA)
- Mathematical Analysis (AREA)
- Mathematical Optimization (AREA)
- Pure & Applied Mathematics (AREA)
- Computational Mathematics (AREA)
- Bioinformatics & Cheminformatics (AREA)
- Life Sciences & Earth Sciences (AREA)
- Acoustics & Sound (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The application relates to a method for controlling deformation of an aviation thin-walled workpiece by plasma spraying, belongs to the technical field of aerospace materials, and solves the problems that deformation, structural change and even damage are caused because deformation cannot be controlled in the process of plasma spraying of the aviation thin-walled workpiece in the prior art. The invention provides a plasma spraying deformation control method for an aviation thin-walled part, which comprises the following steps: measuring the residual stress of the material at each part of the thin-wall part; inputting boundary conditions in simulation software, and establishing a plasma spraying finite element model of the thin-wall part; outputting a corresponding deformation model and a stress model based on the input boundary conditions; the effectiveness of the thin-wall part plasma spraying finite element model is judged by combining the stress model and the measured stress value; the deformation condition of the aviation thin-walled workpiece under different spraying conditions is simulated through an effective plasma spraying model, the optimal plasma spraying process is determined, and the plasma spraying deformation control of the aviation thin-walled workpiece is realized. The detection, prediction and correction of the plasma spraying deformation of the aviation thin-wall part are realized.
Description
Technical Field
The application relates to the technical field of aerospace materials, in particular to a method for controlling deformation of an aviation thin-walled part through plasma spraying.
Background
The plasma spraying technology is to heat and melt the spraying powder through plasma flame to form a coating on the surface of a substrate, the central temperature of the spraying flame is as high as 15000K, almost any material can be melted and sprayed through the plasma spraying, the formed coating has the advantages of high particle spraying speed, compact coating, high bonding strength, difficult oxidation of the spraying material and the like due to the fact that inert gas is used as working gas, and the plasma spraying application range is wide. Therefore, the method has important application in the high-tech field, such as the fields of medical and health prosthetic appliances and aerospace materials.
However, the application process of the thin-walled aviation components commonly used in the aerospace field has problems. The aviation thin-wall material is a special structural member with a thin wall thickness not exceeding 3 mm. Due to the special requirements of the aerospace field on aerodynamics, the materials are often complex in structure and difficult to process. Meanwhile, the aerospace field has high requirements for light weight of materials, and the rigidity is low due to low thickness of the materials. Moreover, the most common mode of the pretreatment of the materials is sand blasting treatment, the sand blasting method is used for pretreating the surface of the materials, the residual stress on the surface of the thin-walled part processed in the early stage can be released in the further plasma spraying process, the plasma arc spraying flame flow has the characteristics of high temperature, high jet flow speed and the like, and the stress concentration of certain parts of the thin-walled part can be caused in the plasma spraying process to damage the matrix structure. Therefore, controlling the stress superposition and concentration of the thin-wall part becomes an important bottleneck restricting the processing and the use of the thin-wall part, and is a problem which needs to be solved at present.
Disclosure of Invention
In view of the foregoing analysis, the present application aims to provide a method for controlling deformation of an aviation thin-wall part by plasma spraying, so as to solve one of the following technical problems: (1) the deformation of the existing aviation thin-wall part in plasma spraying can not be controlled or is difficult to be accurately controlled, so that the problems of deformation, structural change and even damage are caused; (2) the aviation thin-wall part is difficult to be effectively corrected after being deformed in the plasma spraying process.
The purpose of the application is mainly realized by the following technical scheme:
the method for controlling the deformation of the aviation thin-walled workpiece by plasma spraying is characterized by comprising the following steps of:
when the output value of the stress model is consistent with the stress measured value, the plasma spraying finite element model of the thin-wall part is effective;
when the output value of the stress model does not accord with the stress measured value, the thin-wall part plasma spraying finite element model is invalid, the step 3 and the step 4 are sequentially repeated, and the boundary condition is readjusted until the effective thin-wall part plasma spraying finite element model is established;
and 5, simulating the deformation condition of the aviation thin-walled part under different spraying conditions through the effective thin-walled part plasma spraying finite element model, determining an optimal plasma spraying process, and realizing the plasma spraying deformation control of the aviation thin-walled part.
Further, in step 2, the boundary conditions include material, fixing mode, scanning speed and heat source.
Further, in the step 4, an object of the adjustment of the boundary condition is a heat source function.
Further, the heat source function model is:
q is the heat flux density of the plasma jet; r is the distance from any point to the center of the circle of the interaction between the plasma jet and the component; r isNFor plasma jet heat sourceA thermal radius; q. q.smIs the heat flux density at the center of the plasma jet.
Further, in the heat source function model, the heat flow density q of the plasma jet centermSatisfies the following conditions:
wherein P is the spray power.
Further, the spraying power P satisfies:
P＝ηIU
wherein I is spraying current; u is spraying voltage; η is the energy absorption rate of the material.
Further, in step 1, the stress is measured using ultrasonic measurement.
Further, in the step 1, setting a sampling point every 1-3mm, and using an interpolation calculation method to approximately represent the stress distribution state of the thin-wall part to obtain the stress values of all parts of the thin-wall part in different states.
Further, after step 4 and before step 5, the method further comprises:
and further verifying the effectiveness of the model based on the effective thin-wall part plasma spraying finite element model. Specifically, the validity of the model is further verified by changing part or all of the boundary condition value variables.
Further, step 5 is followed by:
and 6, simulating the deformation condition of the thin-wall part subjected to shape correction by applying an external force through an effective thin-wall part plasma spraying finite element model, and taking the determined optimal shape correction condition as the shape correction condition of the thin-wall part real object.
Compared with the prior art, the application can realize at least one of the following beneficial effects:
(1) according to the method, the stress area and the stress size of the aviation thin-wall part are measured through stress detection, the plasma spraying model of the aviation thin-wall part is established through setting reasonable boundary conditions, the stress model and the deformation model of the aviation thin-wall part in plasma spraying are simulated, the conformity of the stress model and the deformation model is verified based on the stress detection and the plasma spraying model, an effective model which conforms to the deformation of the aviation thin-wall part in the real plasma spraying process is established, the stress concentration condition and the deformation condition of the aviation thin-wall part under different plasma spraying conditions can be simulated through the effective model, and technical support is provided for a subsequent shape correction scheme.
(2) According to the method and the device, the boundary conditions for establishing the effective plasma spraying model are determined, the boundary conditions comprise materials, a fixing mode, a scanning speed and a heat source, and particularly the setting of a heat source function, so that the consistency of a stress detection result and a plasma spraying model result is good, and the stress concentration condition and the deformation condition of the aviation thin-wall part under different plasma spraying conditions can be truly reflected.
(3) According to the method, stress detection and simulation are combined, the deformation trend and the deformation of the thin-wall part are calculated and predicted by constructing an effective model, and the influence of each parameter on deformation in the spraying process can be inspected, so that the optimal spraying parameter is selected, and the deformation control of the plasma spraying process of the aviation thin-wall part is realized.
(4) According to the method, stress detection and simulation are combined, an effective model is constructed to calculate and predict the deformation trend and deformation amount of the thin-wall part, the deformation condition of the thin-wall part subjected to shape correction by applying an external force is simulated through the effective thin-wall part plasma spraying finite element model, the relation between a shape correction factor and a shape correction result can be investigated, the optimal shape correction condition is finally determined, the determined optimal shape correction condition is used as the shape correction condition of a thin-wall part real object, and effective shape correction of deformation in the process of plasma spraying of the aviation thin-wall part can be achieved.
In the present application, the above technical solutions may be combined with each other to realize more preferable combination solutions. Additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the application. The objectives and other advantages of the application may be realized and attained by the structure particularly pointed out in the written description and drawings.
Drawings
The drawings are only for purposes of illustrating particular embodiments and are not to be construed as limiting the application, wherein like reference numerals are used to designate like parts throughout.
FIG. 1 is a plasma spray simulation model;
FIG. 2a is a distribution diagram of sampling points for a reverse stress test according to an embodiment;
FIG. 2b is a distribution diagram of sampling points for a front stress test according to an embodiment;
FIG. 2c is a graph showing the results of a back stress test before blasting according to one embodiment;
FIG. 2d is a graph showing the results of the front stress test before blasting according to one embodiment;
FIG. 2e is a graph showing the results of the back stress test after sand blasting according to example one;
FIG. 2f is a graph showing the results of the front stress test after sandblasting in one embodiment;
FIG. 2g is a graph showing the results of the reverse stress test after the spray coating of the first embodiment;
FIG. 3 is a deformation model before and after sandblasting and before and after spraying according to an example;
FIG. 4 is a graph showing the results of a material simulation analysis according to one embodiment;
FIG. 5 is a diagram illustrating simulation analysis results in a fixed manner according to an embodiment;
FIG. 6 is a graph showing the results of a scan velocity simulation analysis according to an embodiment;
FIG. 7 is a graph showing the results of a power simulation analysis according to one embodiment.
Detailed Description
The plasma spraying technology is to heat and melt the spraying powder through plasma flame to form a coating on the surface of a substrate, the central temperature of the spraying flame is up to more than 15000K, and the plasma spraying has a plurality of advantages and wide application. However, for common aviation thin-wall parts in the aerospace field, the wall thickness is not more than 3mm, the requirement for light weight is high, and the rigidity is low. The most common mode of the pretreatment of the material is sand blasting treatment, the surface of the material is pretreated by a sand blasting method, the residual stress on the surface of a thin-walled part processed in the early stage can be released in the further plasma spraying process, the plasma arc spraying flame flow has the characteristics of high temperature, high jet flow speed and the like, and the stress concentration of certain parts of the thin-walled part can be caused in the plasma spraying process to damage the matrix structure. Therefore, in the thin-wall part machining process, the deformation of the thin-wall part caused by the superposition and concentration of the stress of the thin-wall part becomes an important bottleneck restricting the machining and the use of the thin-wall part, and the problem to be solved at present is also needed.
Considering that the deformation control process of plasma spraying is very complicated, in order to realize the control of the deformation control process of plasma spraying, the spraying process needs to be detected, the deformation condition is predicted according to the detection condition, and the predicted result and the actual deformation result are corrected and changed.
According to the consideration, the method for controlling the plasma spraying deformation of the aviation thin-wall part comprises stress testing, simulation and deformation control, and the stress concentration and deformation conditions of the pretreatment process and the spraying process are judged by combining the results of the stress testing and the simulation.
In the pretreatment process of plasma spraying, in order to realize the roughening of the surface of the thin-wall part before spraying, the surface of the aviation thin-wall part is roughened under the strong action of sand blasting, and the thin-wall part is sprayed under the impact force of high-temperature spray materials melted by plasma flame. Therefore, the stress of the thin-wall part in the pretreatment process can be detected to provide certain stress condition detection.
The application discloses a method for controlling deformation of an aviation thin-walled workpiece through plasma spraying, which comprises the following steps:
when the output value of the stress model is consistent with the stress measured value, the plasma spraying finite element model of the thin-wall part is effective;
when the output value of the stress model does not accord with the stress measured value, the thin-wall part plasma spraying finite element model is invalid, the step 3 and the step 4 are sequentially repeated, and the boundary condition is readjusted until the effective thin-wall part plasma spraying finite element model is established;
and 5, simulating the deformation condition of the aviation thin-walled part under different spraying conditions through the effective thin-walled part plasma spraying finite element model, determining an optimal plasma spraying process, and realizing the plasma spraying deformation control of the aviation thin-walled part.
Specifically, the stress detection uses an ultrasonic measurement method.
The propagation speed of the ultrasonic wave has a certain relation with the change of the stress in the material, and the model is constructed according to the change relation of the material stress and the propagation speed of the ultrasonic wave which are quantitatively expressed.
The principle of the ultrasonic stress detector is as follows: the phase change formula of the small-amplitude surface wave when the small-amplitude surface wave is propagated in the super-elastic body interface with the initial stress indicates that after the ultrasonic surface wave transmits a certain sound path in the material of the stress field T at the initial speed v, a certain phase offset can occur:
where Φ (ω) is the phase; ω is the angular frequency of the surface wave; p is the mean value of the surface wave energy flow over time; v is the region of surface wave propagation within the undeformed elastomer; x is the displacement gradient of the surface wave; g is a function of the displacement gradient x of the surface wave with respect to the material and the angular frequency ω of the surface wave.
The stress detection can only provide the stress condition of the material, how to obtain the shape change trend of the stressed aviation thin-wall part by using the material characteristics, the fixing mode, the heating and other factors, and the establishment of the conversion and expression between the stress and the deformation is the key for solving the problem.
Although simulation can represent the machining process of a thin-wall part under certain conditions to a certain extent, the set parameters and the actual operating environment often have certain errors, so that the simulation cannot be used as an instructive tool in engineering and can only be used as a reference. In order to truly reflect the parameters of the actual operating environment, the method is a feasible implementation method that a mechanical model is established according to actual mechanical detection data, the shape change trend of the stressed aviation thin-walled part is simulated through computer simulation, and the deformation trend of the stressed aviation thin-walled part is analyzed. Meanwhile, the effectiveness of the simulation model and stress detection under the condition is judged by combining the simulation model and the actual deformation condition, and then the optimal spraying condition for controlling deformation is obtained by changing part of variables in the simulation process and the verification of an actual product; on the basis, the deformation condition of the thin-wall part is judged after cold correction is carried out by simulating external force through simulation software, the deformation condition of the thin-wall part obtained through judgment is used as the physical deformation condition, and a physical object is used as a correction object to find out the optimal correction method. Therefore, in order to realize the control of the plasma spraying deformation of the aviation thin-wall part, the deformation condition of the thin-wall part generated by the stress concentration in the pretreatment process and the spraying process is judged by combining the stress test result and the simulation.
Setting simulation boundary conditions: the method selects materials, a fixing mode, a scanning speed and a heat source as boundary conditions to establish an aviation thin-walled workpiece plasma spraying model, and uses the heat source as a key object for boundary adjustment.
Different materials have different compositions, various elements have unique atomic structures, and the material has influence on various mechanical and thermal properties, especially the absorption of the aviation thin-wall part on energy is directly influenced by different material types.
The fixing mode comprises edge fixing, center fixing, angle fixing and other modes, the fixing mode is directly related to the stress of the thin-wall part, and different fixing modes can influence the stress change of different areas of the thin-wall part when the thin-wall part is subjected to plasma spraying, so that the fixing mode is one of important boundary conditions.
The speed of the scanning speed directly influences the accumulation degree of continuous stress of each stress point of the material, and therefore is also an important boundary condition.
The heat source is the most important boundary condition, the heat source directly influences the heating condition of the thin-wall part, and after the thin-wall part is heated, the internal structural force of the material of the thin-wall part is necessarily changed to influence the deformation of the thin-wall part.
Specifically, the initial temperature of the sample before the plasma spraying operation was started was 20 ℃ which was the same as the ambient temperature. In order to truly simulate the heat radiation effect of a plasma heat source of a spray gun on a thin-wall part, the heat source with certain heat flux is arranged to scan the surface of the thin-wall part along a certain path. And then cooling to room temperature.
The plasma spraying is characterized in that high-temperature plasma jet generated by a non-transferable electric arc is used as a heat source, and according to the temperature distribution condition of the plasma jet, the plasma spraying heat source is simplified into a Gaussian heat source, and the expression of a heat source function is shown as the following formula:
P＝ηIU
wherein q is the heat flux density of the plasma jet; r is the distance from any point to the center of the circle of the interaction between the plasma jet and the component; r isNIs the heating radius of the plasma jet heat source; q. q.smHeat flux density at the center of the plasma jet; p is spraying power (in calculation, the plasma spraying power is kept unchanged); i is spraying current; u is spraying voltage; η is the energy absorption rate of the material.
Specifically, the simulation software may select Comsol simulation software. Inputting parameters such as thermal conductivity, thermal expansion coefficient, density, specific heat capacity and the like of thin-wall piece materials (TA15, GH3536, GH99 and Ti60) as intrinsic characteristics of the materials in the column of Comsol simulation software 'materials'; then, adding a column of 'solid heat transfer' in the software, and adding a 'point heat source' in the column, wherein the point heat source formula is shown as a Gaussian heat source formula in the step 5, and the scanning speed is correspondingly increased in the column; and then, perfecting relevant contents of 'solver configuration' in the software, including setting fixed conditions (the fixed point of the simulation piece in the software can be set by manually clicking a fixed point), and clicking 'drawing', so that a 'deformation' model of the simulation piece under corresponding conditions, namely a deformation condition model of the simulation piece, and a 'stress' model, namely a stress distribution model of the simulation piece can be respectively obtained. The model constructed can be as in figure 1. On the basis of the model construction, corresponding parameters are changed and a deformation model and a stress model are respectively drawn so as to intuitively simulate the influence of different parameters on the deformation and stress of the thin-wall part.
After the model is established, the influence of materials needs to be considered, the simulation can be carried out by analyzing the common materials of the thin-wall parts in the aerospace field such as TA15, GH3536, GH99 and Ti60, the obtained residual stress and total displacement are detected after the sand blasting, the spraying and the standing cooling are carried out for more than 10 minutes, and the simulation model of the residual stress distribution and the deformation tendency of the surface of the thin-wall part subjected to the plasma spraying by the materials is constructed.
Then, the influence of the fixing mode needs to be considered, and simulation models of the residual stress distribution and the deformation trend of the surface of the plasma spraying thin-walled workpiece under four different fixing supports, namely the short side, the long side, the diagonal and the four corners, are respectively constructed.
Then, the influence of the scanning speed is examined, and a simulation model of the residual stress distribution and the deformation trend of the surface of the plasma spraying thin-wall part at three different scanning speeds of 50mm/s, 200mm/s and 500mm/s can be constructed.
Finally, the influence of the heat flux is considered, and a simulation model of the residual stress distribution and deformation trend of the surface of the plasma spraying thin-wall part under different heat fluxes caused by four different spraying powers of 50W, 100W, 200W and 400W can be constructed.
Specifically, the combination of simulation and stress test results analyzes the deformation mechanism of the thin-wall part and judges the stress concentration and deformation conditions of the pretreatment process and the spraying process, and the method comprises the following steps:
the most intuitive stress distribution obtained by stress detection, a model obtained by simulation and simulation are qualitatively compared with the actual deformation condition, the simulation model with larger stress value is characterized as larger deformation, and the simulation model with smaller stress value is characterized as smaller deformation; the concave surface exhibiting tensile stress should exhibit a tendency to shrink in a subsequent processing step.
And comparing the result of the stress detection analysis with a deformation model obtained by spraying simulation and the actual deformation condition, and judging the effectiveness of the stress detection and the setting of the simulation parameters in the model. Then, through simulation software, changing several main process parameters influencing spraying and changing a certain variable of the software, analyzing the deformation condition and finding out the optimal parameters influencing deformation; meanwhile, the optimal method for cold correction of the deformed simulation piece is found out by simulating the deformation condition of the simulation piece after external force is applied.
Specifically, the correction includes: correcting and preventing the stress by using external force in the stress concentration area;
and carrying out deformation correction on the deformation area by using external force.
Specifically, the deformation correction of the deformed region by an external force includes applying a mechanical force to the deformed region to eliminate or reduce the shape change of the deformed region.
It should be noted that stress correction and deformation prevention should be performed for the stress concentration region, and in one possible embodiment, by reinforcing the reinforcing bars. In another possible embodiment, stress can be corrected and denaturation prevented by thickening the stress concentration region.
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate preferred embodiments of the application and together with the description, serve to explain the principles of the application and not to limit the scope of the application.
Example one
The application discloses a method for controlling deformation of an aviation thin-walled workpiece through plasma spraying.
Stress detection of aviation thin-wall part
The stress distribution conditions of the aviation thin-walled part before and after plasma spraying are measured by an ultrasonic stress measuring instrument. Setting a sampling point every 2mm, and then using an interpolation calculation method to approximately represent the stress distribution state of the thin-wall part to obtain the stress values of all parts of the thin-wall part in different states. The resulting graph is shown in FIG. 2, for example. The values noted for the model in fig. 2 are the measured stress values. According to the measured stress value, in an initial state, the thin-wall part has larger stress, the area with larger stress is mainly distributed at the positions of the reinforcing ribs, the edges, the processing bosses and the like, the inner surface and the outer surface of the thin-wall part have tensile stress of different degrees, and the tensile stress of the side with the reinforcing ribs is relatively larger.
One surface of the reinforcing rib is a concave surface, so that after spraying, the tensile stress is released, the thin-wall part can shrink to a certain degree, but the deformation of the thin-wall part is just opposite to that of the thin-wall part before sand blasting, and the deformation of the thin-wall part before sand blasting is just relieved to a certain degree.
Simulation of aviation thin-walled part
A thin-wall part of an aviation fuselage made of GH99 material is used as a test piece, Comsol multi-physical-field simulation software is used for respectively constructing simulation models of different materials, different fixing modes, scanning speeds and different heat fluxes, and the influence of the influence factors on the deformation tendency of the thin-wall part is analyzed.
(1) Deformation model of typical part before and after sand blasting
As shown in fig. 3, the simulated deformation model of the typical part before and after sand blasting and before and after spraying is visualized by the model, the deformation of the typical part before and after sand blasting and before and after spraying is mainly located at the edge of the thin-wall part, the reinforcing rib, the boss and other parts, the trend is consistent with the stress distribution obtained by stress detection, namely, the part with larger stress is correspondingly larger in deformation in the next processing process; and after spraying, the deformation difference of each part of the typical part is relatively reduced, namely the integral uniformity is improved, namely the deformation of the typical part before sand blasting is relieved to a certain extent after spraying.
The expression of the heat source function is shown as follows:
P＝ηIU
wherein q is the heat flux density of the plasma jet; r is the distance from any point to the center of the circle of the interaction between the plasma jet and the component; r isNIs the heating radius of the plasma jet heat source; q. q.smHeat flux density at the center of the plasma jet; p is spraying power (in calculation, the plasma spraying power is kept unchanged); i is spraying current; u is spraying voltage; η is the energy absorption rate of the material.
(2) Influence of different materials
Two different materials, TA15 and GH99 alloy, were selected for analysis in the simulation, and the resulting residual stress and total displacement were measured after sand blasting, spray coating, and standing cooling for 10min (600 s). The simulation parameters are shown in table 1, and the simulation analysis results are shown in fig. 4.
According to the analysis result, the deformation trend after spraying accords with the deformation trend of stress analysis and the actual deformation condition, and the effectiveness of stress detection and thin-wall parts is verified. Therefore, in the later stage, the scheme of changing parameters such as different fixing modes and the like in the simulation model to simulate the minimum deformation of the thin-wall part is adopted.
TABLE 1 simulation parameters for different materials
(3) Influence of different fixing modes
And (3) constructing a simulation model of the residual stress distribution and the deformation trend of the surface of the plasma spraying thin-walled workpiece under different fixed supports, wherein specific simulation parameters are shown in a table 2, and a simulation analysis result is shown in a figure 5.
TABLE 2 simulation parameters for different fixing modes
(4) Influence of different scanning speeds
And (3) constructing a simulation model of the residual stress distribution and the deformation trend of the surface of the plasma spraying thin-walled workpiece at different scanning speeds, wherein specific simulation parameters are shown in a table 3, and a simulation analysis result is shown in a figure 6.
TABLE 3 simulation parameters for different scanning speeds
(5) Influence of different heat fluxes
And (3) constructing a simulation model of the residual stress distribution and the deformation trend of the surface of the plasma spraying thin-walled workpiece under different heat fluxes, wherein specific simulation parameters are shown in a table 4, and a simulation analysis result is shown in a figure 7.
TABLE 4 different Heat flux simulation parameters
From the constructed simulation model, it can be seen that: the deformation of GH99 is obviously greater than that of TA15 alloy, larger elastic deformation is generated under the condition of full fixation, and the plastic irreversible deformation generated by the second step is higher by one order of magnitude;
in the simulation process, the deformation of the simulation piece is minimum under the condition that the simulation piece is sprayed when the shortest side is fixed. Therefore, the deformation of the simulation piece can be effectively reduced by selecting the short edge spraying mode;
the residual stress is mainly distributed in the fixed area of the thin-wall part, and the maximum stress value can reach hundreds of MPa. Meanwhile, as the scanning speed of the spray gun is increased, the surface residual stress of the thin-wall part tends to be smaller, and the deformation is smaller;
the residual stress and deformation of the thin-wall part can be slightly increased due to the increase of the energy of the heat source, but the change is not large, namely the deformation of the thin-wall part per se is less influenced by the heat flux within a certain range.
Therefore, in the spraying process, the deformation of the thin-wall part in the spraying process can be effectively reduced by adopting a faster scanning speed (500mm/s) and a short-side fixed spraying mode.
Deformation control of aviation thin-wall part
Aiming at the deformed thin-wall part, a simulation model with the same fixing mode, the same material (GH99) and the same spraying power (75W) is created according to the simulation part machining process, and the cold correction of the thin-wall part by applying external force at the position with the maximum stress distribution is selected by combining the position with the maximum stress distribution detected in the early stage, namely the machining hole, the reinforcing rib and the like. And applying a force of 1KN near a second machining hole on the deformed aviation thin-wall part by using an optimal solution selected by simulation, and after acting for 1 minute, effectively improving the deformation of the aviation thin-wall part and comparing a profile scanning diagram before and after the action.
As can be seen from the profile scanning chart, the deformation of the simulation piece is reduced from 0.64 maximum to about 0.14 maximum by the shape correction mode, and the measures are effective.
The above description is only for the preferred embodiment of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present application should be covered within the scope of the present application.
Claims (10)
1. The method for controlling the deformation of the aviation thin-walled workpiece by plasma spraying is characterized by comprising the following steps of:
step 1, measuring the residual stress of materials of all parts of the thin-wall part before and after plasma spraying;
step 2, inputting boundary conditions in finite element simulation software, and establishing a plasma spraying finite element model of the thin-wall part;
step 3, outputting a deformation model and a stress model corresponding to the boundary condition based on the input boundary condition;
step 4, combining the stress model output in the step 3 and the stress value measured in the step 1, and judging the effectiveness of the plasma spraying finite element model of the thin-wall part;
when the output value of the stress model is consistent with the stress measured value, the plasma spraying finite element model of the thin-wall part is effective;
when the output value of the stress model does not accord with the stress measured value, the thin-wall part plasma spraying finite element model is invalid, the step 3 and the step 4 are sequentially repeated, and the boundary condition is readjusted until the effective thin-wall part plasma spraying finite element model is established;
and 5, simulating the deformation condition of the aviation thin-walled part under different spraying conditions through the effective thin-walled part plasma spraying finite element model, determining an optimal plasma spraying process, and realizing the plasma spraying deformation control of the aviation thin-walled part.
2. The method for controlling plasma spraying deformation of a hollow thin-walled workpiece according to claim 1, wherein in step 2, the boundary conditions include material, fixing mode, scanning speed and heat source.
3. The method for controlling plasma spraying deformation of a hollow thin-walled workpiece according to claim 1, wherein in the step 4, the adjustment object for adjusting the boundary condition is a heat source function.
4. The method for controlling plasma spraying deformation of a hollow thin-walled workpiece according to claim 3, wherein the heat source function model is:
q is the heat flux density of the plasma jet; r is the distance from any point to the center of the circle of the interaction between the plasma jet and the component; r isNIs the heating radius of the plasma jet heat source; q. q.smIs the heat flux density at the center of the plasma jet.
5. The method for controlling plasma spraying deformation of a hollow thin-wall part according to claim 4, wherein in the heat source function model, the heat flow density q at the center of the plasma jet ismSatisfies the following conditions:
wherein P is the spray power.
6. The plasma spraying deformation control method of a hollow thin-walled workpiece according to claim 5, wherein the spraying power P satisfies:
P＝ηIU
wherein I is spraying current; u is spraying voltage; η is the energy absorption rate of the material.
7. The method for controlling plasma spraying deformation of a hollow thin-walled workpiece according to claim 1, wherein in step 1, the stress is measured by an ultrasonic measurement method.
8. The plasma spraying deformation control method for the hollow thin-walled workpiece according to claim 1, wherein in the step 1, a sampling point is arranged every 1-3mm, and the stress distribution state of the thin-walled workpiece is approximately represented by using an interpolation calculation method, so that the stress values of all parts of the thin-walled workpiece in different states are obtained.
9. The method for controlling the plasma spraying deformation of a hollow thin-wall part according to claim 1, wherein after step 4 and before step 5, the method further comprises:
and further verifying the effectiveness of the model based on the effective thin-wall part plasma spraying finite element model.
10. The method for controlling the plasma spraying deformation of a hollow thin-walled workpiece according to claim 1, wherein step 5 is followed by further comprising:
and 6, simulating the deformation condition of the thin-wall part subjected to shape correction by applying an external force through an effective thin-wall part plasma spraying finite element model, and taking the determined optimal shape correction condition as the shape correction condition of the thin-wall part real object.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011555697.0A CN112651157B (en) | 2020-12-24 | 2020-12-24 | Aviation thin-walled part plasma spraying deformation control method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011555697.0A CN112651157B (en) | 2020-12-24 | 2020-12-24 | Aviation thin-walled part plasma spraying deformation control method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN112651157A true CN112651157A (en) | 2021-04-13 |
| CN112651157B CN112651157B (en) | 2022-04-19 |
Family
ID=75362769
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011555697.0A Active CN112651157B (en) | 2020-12-24 | 2020-12-24 | Aviation thin-walled part plasma spraying deformation control method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112651157B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113343521A (en) * | 2021-05-27 | 2021-09-03 | 重庆大学 | Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070054062A1 (en) * | 2004-10-15 | 2007-03-08 | Yukio Imaizumi | Method of thermal spraying |
| CN105302970A (en) * | 2015-11-04 | 2016-02-03 | 沈阳黎明航空发动机(集团)有限责任公司 | Prediction method of residual stress-redistribution process of thin-walled aviation part |
| CN106909714A (en) * | 2017-01-19 | 2017-06-30 | 西南交通大学 | A kind of thin-wall member electric arc silk filling increasing material manufacturing temperature field prediction method |
| CN109583037A (en) * | 2018-11-06 | 2019-04-05 | 西北工业大学 | A kind of parameter control method of blade of aviation engine shot-peening machining deformation |
-
2020
- 2020-12-24 CN CN202011555697.0A patent/CN112651157B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070054062A1 (en) * | 2004-10-15 | 2007-03-08 | Yukio Imaizumi | Method of thermal spraying |
| CN105302970A (en) * | 2015-11-04 | 2016-02-03 | 沈阳黎明航空发动机(集团)有限责任公司 | Prediction method of residual stress-redistribution process of thin-walled aviation part |
| CN106909714A (en) * | 2017-01-19 | 2017-06-30 | 西南交通大学 | A kind of thin-wall member electric arc silk filling increasing material manufacturing temperature field prediction method |
| CN109583037A (en) * | 2018-11-06 | 2019-04-05 | 西北工业大学 | A kind of parameter control method of blade of aviation engine shot-peening machining deformation |
Non-Patent Citations (6)
| Title |
|---|
| 吴娇等: "基于ANSYS的Q235与1Cr18Ni9Ti异种钢焊接工艺参数优化", 《应用激光》 * |
| 张洪伟等: "航空结构件加工变形仿真关键技术", 《北京航空航天大学学报》 * |
| 李巧彦: "参数化的船体平板分段焊接变形预测", 《中国优秀博硕士学位论文全文数据库(硕士)工程科技Ⅱ辑》 * |
| 杨凯朝等: "ANSYS有限元法在焊接温度场分析中的应用", 《铸造技术》 * |
| 翁礼杰: "等离子喷涂HA复合涂层工艺参数优化与残余应力分析", 《中国优秀博硕士学位论文全文数据库(硕士)工程科技Ⅰ辑》 * |
| 虞钢 等: "《激光先进制造技术及其应用》", 31 December 2016, 北京：国防工业出版社 * |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113343521A (en) * | 2021-05-27 | 2021-09-03 | 重庆大学 | Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL |
Also Published As
| Publication number | Publication date |
|---|---|
| CN112651157B (en) | 2022-04-19 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Huang et al. | Prediction of laser welding induced deformation in thin sheets by efficient numerical modeling | |
| Montevecchi et al. | Finite element modelling of wire-arc-additive-manufacturing process | |
| CN112651157B (en) | Aviation thin-walled part plasma spraying deformation control method | |
| CN107301261A (en) | Simulated based on COMSOL temperature models and calculate Laser Processing and the method in temperature field in welding process | |
| Xu et al. | Welding deformation of ultra-thin 316 stainless steel plate using pulsed laser welding process | |
| CN110102924A (en) | A method of for controlling correction large-size box structural member fillet weld deformation | |
| Colodrón et al. | Performance improvement of a laser cladding system through FPGA-based control | |
| Liu et al. | Nonlinear vibration modeling and analysis of bolted thin plate based on non-uniformly distributed complex spring elements | |
| Ma et al. | Thermo-mechanical coupled in situ fatigue device driven by piezoelectric actuator | |
| CN112475659A (en) | Method for simulating crack behavior sequence of linear friction welding and joint CT sample thereof | |
| Zhao et al. | A novel finite element method for simulating residual stress of TC4 alloy produced by laser additive manufacturing | |
| CN111638242A (en) | Method for improving accuracy of welding thermal simulation test on thermal simulation testing machine | |
| Russell et al. | Analytical modelling of friction stir welding | |
| Ferro et al. | Calculation of 3D residual notch stress intensity factors by means of the peak stress method | |
| CN108581165A (en) | A kind of oxygen-free copper welding parameter of electron beam prediction computational methods | |
| Sheikh et al. | Understanding the effect of non-conventional laser beam geometry on material processing by finite-element modelling | |
| Bingul et al. | Dynamic modeling of GMAW process | |
| Safdar et al. | Thermal history analysis of surface heating of mild steel with different laser beam geometries | |
| Niordson | Analysis of steady-state ductile crack growth along a laser weld | |
| CN114277244A (en) | Deformation-controllable laser shock strengthening method and device for aero-engine blade | |
| Ridgers et al. | Transport in the presence of inverse bremsstrahlung heating and magnetic fields | |
| Jou | Experimental study and modeling of GTA welding process | |
| Reed et al. | The development and validation of a model for the electron beam welding of aero-engine components | |
| Svenungsson | Conduction laser welding: modelling of melt pool with free surface deformation | |
| Dearden et al. | Correction of distortion and design shape in aluminium structures using laser forming |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant | ||
| CB03 | Change of inventor or designer information |
Inventor after: Yu Ling Inventor after: Tian Weizhi Inventor after: Liu Xiaoyu Inventor after: Yang Mingjia Inventor before: Yu Ling |
|
| CB03 | Change of inventor or designer information |