压气机叶片辊轧模具型腔回弹补偿方法研究  

Investigation on Springback Compensation Method for the Rolling Mold of Compressor Blade

作　　者：靳淇超[1] 汪文虎[1] 蒋睿嵩[1] 赵德中[1] 崔康[1] 

机构地区：[1]西北工业大学现代设计与集成制造技术教育部重点实验室,西安710072

出　　处：《机械工程学报》2017年第16期148-155,共8页Journal of Mechanical Engineering

基　　金：国家自然科学基金(51475374;51505387);中央高校基础科研业务费专项资金(3102015ZY087)资助项目

摘　　要：航空发动机高压压气机叶片在辊轧成形过程中会沿着弦长方向发生回弹,直接影响叶片的成形精度进而影响其气动性能。为实现航空发动机压气机叶片无余量辊轧成形,提出并研究基于截面线回弹补偿的叶片辊轧模腔优化设计方法。分析钣金件弯曲变形过程并基于钣金件的几何结构和材料特性建立回弹前后中心角的变化模型。在此基础上提出叶片截面回弹补偿模型,并对辊轧叶片工艺模型截面进行回弹误差补偿。将回弹补偿后的叶片工艺模型截面线族绕轧辊轴线进行扇态分布并重构辊轧模具型腔。基于数值计算方法使用几何映射和回弹补偿设计的型腔对叶片辊轧成形过程进行模拟,并获得了相应的轧制成形叶片模型。结果表明,回弹补偿后的模具型腔能够有效提高叶片型面的成形精度,叶片成形误差缩小到原来的16.7%。本文研究内容为压气机无余量辊轧成形模具设计提供理论支撑,同时对不规则薄壁类结构塑性成形精度控制具有参考价值。A springback along the chord-wise direction is occurred in the rolling process of the high pressure compressor blade in aero-engine, which affects the accuracy of the blade profile directly and then affects the service performance of the engine. In order to achieve the net-shape of the compressor blade for the aero-engine by rolling, an optimized designing method is presented to improve the accuracy of rolling cavity surface by mapping transformation of the section curves, which compensated the springback on the original section contours. The deformation of the sheet metal in bending process is analyzed, and a model which described the variation of central angle before and after springback is studied. After that, a springback compensation method for blade section is proposed and the springback deviation of every process model＇s section curve is compensated. The springback compensated section curves are mapped to a sector in three dimension around the rollers＇ axes, and the rolling cavity surfaces are reconstituted through the mapped section curves. An effective numerical calculation method is used to simulate the blade rolling process by both the original cavity surfaces and the springback compensated cavity surfaces in order to obtain the shapes of corresponding deformed blades. The results show that the optimal designing of mold cavity can improve the precision of compressor blade profile effectively, and that the deviation of the deformed blade is decreased to 16.7% comparing with the original results. The springback compensating method, which provides a theoretical foundation for designing roller cavity surfaces, would contribute to achieving the net shape profile of the rolling compressor blade. Meanwhile, the method offers a foundation for improving the precision of the irregular sheet metal in plastic deformation.

关 键 词：压气机叶片 截面线 回弹补偿 轧辊模腔 优化设计 成形精度 

分 类 号：TG335[金属学及工艺—金属压力加工]