大尺寸空心涡轮叶片一体化陶瓷铸型冷冻干燥应力仿真分析  

Simulation Analysis of Freeze-Drying Stress in Integrated Ceramic Casting Mold of Large-Sized Hollow Turbine Blade

作　　者：刘岩[1] 周子明 艾子超 牛夕莹 徐云龙 李宗全 鲁中良[1] 苗恺[1] 陈世斌 曹福升 王林 李涤尘[1] LIU Yan;ZHOU Ziming;AI Zichao;NIU Xiying;XU Yunlong;LI Zongquan;LU Zhongliang;MIAO Kai;CHEN Shibin;CAO Fusheng;WANG Lin;LI Dichen(State Key Laboratory for Manufacturing System Engineering,Xi'an Jiaotong University,Xi'an 710054,China;School of Construction Machinery,Chang'an University,Xi'an 710064,China;No.703 Research Institute,China State Shipbuilding Corporation Limited,Harbin 150007,China)

机构地区：[1]西安交通大学精密微纳制造技术全国重点实验室,西安710054 [2]长安大学工程机械学院,西安710064 [3]中国船舶集团有限公司第七〇三研究所,哈尔滨150007

出　　处：《航空制造技术》2025年第3期76-82,共7页Aeronautical Manufacturing Technology

基　　金：国家科技重大专项(J2019-Ⅱ-0018-0039)。

摘　　要：大尺寸空心涡轮叶片一体化陶瓷铸型在冷冻干燥过程中容易产生裂纹,针对该问题进行了铸型应力分布规律的研究。通过有限元仿真建立了铸型收缩受阻产生应力的理论模型,分析了不同冻干收缩率、铸型壁厚和曲率对铸型冷冻干燥应力的影响,采用变壁厚对铸型尾缘进行了结构优化。研究发现,在冷冻干燥过程中,一体化陶瓷铸型所受应力随着收缩率增大而线性增大,且铸型尾缘曲率最大处承受的应力最大。通过尾缘变壁厚的结构优化设计增大了尾缘处铸型冷冻干燥过程中的抗弯强度,当试样厚度从4 mm增至7 mm时,坯体平均强度从8.32 MPa提升至11.81 MPa。本研究制备了结构完整的一体化陶瓷铸型并进行浇铸验证,得到了陶瓷铸型冷冻干燥的应力分布规律,并提出了尾缘变壁厚结构优化设计的方法,成功解决了一体化陶瓷铸型冷冻干燥过程中产生裂纹的问题。This study focuses on the problem of cracks generated during freeze-drying in the integrated ceramic casting mold of large-sized hollow turbine blade,and studies the stress distribution law of the casting mold.A theoretical model of stress generated by mold shrinkage obstruction was established through finite element simulation.Effects of various freeze-drying shrinkage rates,mold wall thicknesses,and curvatures on mold freeze-drying stress were analyzed.Structural optimization was carried out on trailing edge of the mold using variable wall thickness.It is found that during the freeze-drying process of integrated casting,the stress increases linearly with increase of shrinkage rate,and the stress is the highest at the position with the maximum curvature of the mold trailing edge.By increasing wall thickness at the trailing edge,bending strength of the mold during freeze-drying process is enhanced.When sample thickness increases from 4 mm to 7 mm,average strength of the base substrate increases from 8.32 MPa to 11.81 MPa.The integrated mold with structural integrity is successfully manufactured and verified by casting in this study,stress distribution law of ceramic casting mold and various wall thickness of trailing edge are obtained and proposed,which help to solve the issue of cracks generated during freeze drying for integrated ceramic casting mold.

关 键 词：空心涡轮叶片 一体化铸型 冷冻干燥 变壁厚 应力 

分 类 号：V263[航空宇航科学与技术—航空宇航制造工程]