粉末高温合金盘的切削加工

介绍了粉末高温合金盘的应用和发展趋势,并通过和其他几种材料盘类零件的切削加工情况进行比较,指出了其制造和切削过程中存在的问题,同时探讨了提高粉末高温合金盘切削加工效率的几点措施,包括典型粉末高温合金盘的加工工艺路线以及粉末高温合金盘切削加工对刀具和设备的需求.     

基于缺陷分布形式的粉末冶金涡轮盘可靠度计算模型

为研究微缺陷对粉末冶金涡轮盘可靠性的影响,在有限元分析结果的基础上,基于国内粉末盘中缺陷分布的概率特 点,建立针对低循环疲劳裂纹萌生和裂纹扩展失效模式的可靠度计算模型。该模型可计算不同缺陷分布形式、不同循环载荷条件下的轮盘可靠度。对某型粉末盘失效概率的分析表明：表面质量是导致粉末盘失效的重要因素,这同大量试验研究结果相一致,对粉末盘的设计和使用具有工程指导意义。     

发动机粉末合金高压涡轮盘断裂的原因

某型发动机在进行300h长试试车过程中,材料为FGH4097粉末高温合金的高压涡轮盘发生断裂,造成发动机烧毁,对涡轮盘掉块断口进行宏观、微观观察以及能谱分析,对故障原因进行了排查并对排查结果进行了模拟试验。结果表明:失效的高压涡轮盘为疲劳断裂,涡轮盘疲劳断裂的原因是其冷却孔边存在的夹杂物以及夹杂物周围的大面积原始颗粒边界(PPB),夹杂物主要为电弧焊的焊渣,PPB是焊渣与合金反应生成的伴生物。     

某发动机涡轮盘拉削过程控制研究

某航空发动机涡轮盘是重要部件,材料为FGH95粉末高温合金,在榫槽拉削过程中经常出现拉刀异常磨损和崩齿等问题,造成了较大的经济损失。根据FGH95粉末高温合金特点,分析了其加工难度大的原因,总结了拉削过程的控制要点,提出了拉刀出现问题后的应急处理措施,为FGH95粉末高温合金拉削加工积累了经验。     

拉刀齿升量对GH761合金拉削表面质量的影响

GH761合金是我国自行研制的涡轮盘用新型高温合金,具有优良的综合机械性能,在国内已开始应用于制造多种先进发动机的压气机盘、机匣、涡轮盘等重要零件。但GH761合金塑性大、韧性高、导热性差,切削加工性能较差。为明确压气机盘或涡轮盘榫槽拉削时,拉刀齿升量的大小对拉削表面质量的影响,在液压牛头刨床上进行了模拟拉削工艺试验。     

铣削粉末冶金高温合金FGH95时工件温度的研究

镍基粉末高温合金具有屈服强度高、疲劳性能好等优点,是制造新型发动机涡轮盘的理想材料,工件温度是引起工件各种形式热损伤的主要因素,本文研究铣削粉末冶金高温合金FGH95时工件的瞬态温度。对铣削过程进行合理简化,基于移动热源法建立粉末冶金高温合金铣削时工件温度的解析模型,研究铣削速度对工件温度的影响规律。通过铣削试验对工件温度模型的有效性进行验证,试验结果表明建立的二维工件温度解析模型能正确预测铣削高温合金时工件加工表面的温度分布。     

GH4065A涡轮盘榫槽型面拉削加工变形研究

GH4065A高温合金是通过铸—锻工艺制备的镍基变形高温合金，在700℃以上温度使用时具有与第二代粉末冶金涡轮盘相同的力学性能，适用于新一代航空发动机涡轮盘的制造。在某型GH4065A高温合金涡轮盘榫槽的拉削加工中，存在变形量高达0.1mm以上的情况，导致榫槽型面不合格。针对此问题，分析了导致榫槽型面变形的原因和榫槽不同区域的切削力大小，提出控制变形的解决方案，修正了用于高温合金拉削力计算公式中的C_p及x参数。     

镍基高温合金工件异形孔加工工艺的研究

根据航空发动机涡轮盘上异形孔结构复杂及镍基高温合金材料难加工的特点 ,采用钻削、铣削与磨削工艺的不同组合、选用新型涂层刀具和相应的切削参数进行了工艺试验。通过分析试验过程中刀具、砂轮的磨损(破损 )情况及其对异形孔加工精度和表面粗糙度的影响 ,探讨了铣削、磨削加工镍基高温合金涡轮盘异形孔的可行性。研究结果表明 ,通过优化加工参数 ,涡轮盘异形孔钻削 铣削工艺可有效替代常用的电火花加工工艺。     

某涡轮盘应力计算及优化设计分析

本文以某涡轮盘为模型,利用有限元分析的方法,对几种高温合金材料的涡轮盘进行了应力计算分析。利用AN-SYS参数化语言APDL编写了计算分析涡轮盘剖面参数化成形、应力分析及涡轮盘优化程序。采用一阶优化方法对涡轮盘进行了结构优化设计计算分析,实现了涡轮盘结构的参数化建模和优化设计一体化。试验结果表明改进后的涡轮盘结构合理可靠。     

涡轮盘合金氧化-疲劳裂纹扩展机理和寿命预测研究进展

航空发动机涡轮盘在其服役过程中往往在高温燃气环境下承受热载荷和机械载荷共同作用,最终因疲劳、蠕变以及氧化的交互作用而失效.随着高推重比航空发动机的发展和涡轮前温度的提高,氧化损伤对涡轮盘表面疲劳裂纹扩展的影响愈加显著,往往可使疲劳裂纹扩散速率提高1～2个数量级.综述氧化损伤对涡轮盘用高温合金疲劳裂纹扩展的影响以及疲劳裂纹尖端氧化损伤机理,分析裂纹尖端疲劳损伤、氧化损伤和动态脆化影响裂纹扩展的竞争机制,梳理考虑氧化损伤效应的疲劳裂纹扩展模型和数值模拟方法,对实现氧化-疲劳载荷作用下裂纹扩展速率的准确预测所还需开展的工作进行展望,以期有助于促进航空发动机涡轮盘损伤容限设计方法和工具的发展.     

In-process out-of-roundness measurement probe for turned workpieces

A new in-process and non-contact probe is proposed to measure the diameter and the roundness of turned workpieces. The initial probe discussed in previous publications exhibited diameter measurements with good accuracy (uncertainty 5 μm over 100 mm). This paper discusses the implementation of roundness measurement into the initial probe and its performance. The principle of the roundness measurement is based on the relationship between the displacement and the light intensity. The probe delivers a maximum error of 0.5 μm with an uncertainty of 1 μm for roundness measurement over a range of 100 mm diameter.     

Characterizing cavitation erosion particles by analysis of SEM images

Wear particles produced by vibratory cavitation erosion on stationary-aluminum Al-99.999 were analyzed using scanning electron microscope (SEM), forming a database for further analysis. The particle morphology features were first clarified based on the characteristic stages of the vibratory erosion rate-time pattern. Next, size, area, perimeter and shape factors (elongation and roundness) were determined for eroded particles, using image analysis software. In incubation period, the particles have distinctive characteristics which differed from that for the subsequent periods. These characteristics include the value of longitudinal ratio and roundness factor, limit size range and morphological features such as lamella shape, folding, curving with one of the particle surfaces as the virgin surface. In acceleration, steady-state and attenuation periods, the particles have a wide size range and larger thickness compared with that for the incubation period. The maximum particle size reached about 360 μm in acceleration and steady-state period. For all the cavitation erosion rate periods, the particles were out of sphericity and they have a roundness factor larger than 2. Detailed surface characteristics of the particles produced during cavitation erosion is significant and can open ways for monitoring the cavitation erosion progress.     

火箭发动机涡轮泵高速齿轮的制造

火箭发动机涡轮泵高速齿轮,要求可靠性高。涡轮泵齿轮的制造工艺必须使齿轮具有高的强度和韧性,无潜在缺陷、因加工引起的内应力低、加工表面质量好、尺寸与形状精度高等特性。涡轮泵齿轮制造的最重要工序为精磨齿。文中对磨齿的工艺基准、磨齿裕量、磨齿用量和防止齿面烧伤等问题做了分析,并提出了相应的最佳结果。     

Precision manufacturing of turbine wheel slots by trim-offset approach of WEDM

The present study aims to precisely manufacture the turbine wheel slot using a novel trim-offset approach of wire-electrical-discharge-machining (WEDM) in order to overcome the challenges of a conventional broaching process. Two dimensional model of turbine wheel slot is prepared in ‘ELCAM’ software to generate the computer-numerical-control (CNC) code of fir-tree-profile geometry. The experimental plan based on a trim-offset approach is executed to minimize the thermal damage and to improve the surface fatigue strength, which is most desirable for a long operating life of the jet engine. An average cutting speed of ~1.5 mm/min is observed for rough-cut and ~5 mm/min for trim-cut operation. Six categories of wires are used to manufacture the turbine wheel slots without any wire breakage and gap-short issue. The fabricated profile slots have demonstrated an average roughness (Ra) of 0.65 μm, profile accuracy within ±5 μm, minimum hardness alteration (34.87 Hv), and negligible recast layer (<5 μm) using B-150 wire and fulfilled the essential requirements of the gas turbine industries. Compared to wire-electrochemical-machining (WECM), WEDM trim-offset approach is quite advantageous and should be beneficial for the researchers working in ‘Precision machining of aerospace materials’.     

Impact of die wear and punch surface textures on aluminium can wall

Aluminium can manufacturing uses a wide range of punch sleeve surface roughness and textures. The ironing die and the punch tooling both can vary in the roughness from 0.04 μm to 0.4 μm Ra during the can forming process. This, together with the roughness of the incoming can body sheet (from 0.3 μm to 0.6 μm Ra) creates a wide range of tool/metal interface coefficients of friction. Ironing dies become rougher and have to be replaced frequently once they lose their shape. Punches maintain a consistent roughness for periods of a week to a month and any surface wear is compensated for with die changes. The initial die and punch surface finish adopted by a manufacturing unit determines the long time plant productivity and punch life. A higher friction on the punch side, compared to the die side, is the preferred manufacturing operating condition. Departures from the preferred condition with ground, polished, cross-hatch and media textured punches are examined. Plants that prefer polished carbide punches over cross-hatched must have their lubrication and coolant parameters controlled within a very narrow operating window. A larger operating window and better performance is achieved with the cross-hatch and micro-textured punches having a Ra less than half that of the can body sheet. Above all, a random isotropic texture is identified as the ideal punch sleeve surface texture and the best performer for aluminium can manufacture.     

照明系统中椭球反光碗及方棒的初始结构设计

从能量利用率角度,采用T abu算法对椭球反光碗的初始结构进行了优化,得出椭球反光碗长短轴之比与逃逸能量的变化关系,并对棒状透镜的尺寸的选取做了一定的分析。这为椭球反光碗和棒状透镜初始结构的确定提供了一种可行的方法。     

Detecting oscillation amplitude and defects of hard disk rotating in high speed by laser Doppler technique

Laser Doppler technique is widely used in industry for the purpose of detecting vibration and oscillation. Many researchers have found that using non-contact laser vibrometry to measure surface roughness of disk under dynamic status is more difficult than that of the static condition. In this paper, we proposed a laser Doppler technique for the purpose of measuring the oscillation amplitude and defects of hard disk rotating in high speed. Laser light source, optical Doppler system, detector and data process system were integrated in our experimental system. The whole system was calibrated using a sinusoid generator. The method for converting the measured voltage signals into the corresponding size data was described in detail. It was found that the average size of defects of the hard disk in our experiment is from 1 μm to 5 μm. The developed technique may be useful for quality control in real time in mass production processes.     

A real-time vision system for defect inspection in cast extrusion manufacturing process

The cast extrusion manufacturing process is the initial step which enables the creation of the raw materials, such as clear polypropylene film, needed for the flexible packaging printing process. The current methodology of controlling extrusion-related defect occurrences is attempted by a combination of statistical sampling and human inspection. However, due to the fact that the defects are small in size and hard to visualise in a clear thin film 2 m in width moving at a speed of 50 m/min. This results in poor product quality and high return ratio from customers. To the best of our knowledge, there is no system available that can accurately detect such defects. This research investigates possible defect detection methodologies and has subsequently proposed a system that is capable of real-time monitoring of defects on the cast extrusion manufacturing process. The proposed system utilises the refraction of a collimated light source, which is referred to as Mie light scattering. A vision analysis system is subsequently used to perform a blob analysis to detect the contrasting dark regions of the defects. Two test rigs were constructed to test the feasibility of the system. The first test rig was created to test the theoretical Mie scattering principles and the performance of the image analysis software in practice. The second test rig was created to test the practicability of integrating the Mie scattering theory on the physical cast extrusion line. The results obtained from the tests indicated a success rate of 90% in identifying gels and a 100% success rate in correctly identifying all the die lines presented in the tested samples. It is also deduced that the software has a capability to detect gel granules with a diameter greater than 480 μm and die lines with a thickness greater than 320 μm amid complete repeatability, ensuring that the proposed system fully conforms to the standard industrial requirements.     

Preparation of array micro-holes with large aspect ratio in ZL102

In the past research work, a new preparation of array micro-holes on pure aluminum was proposed. However, in the practical application, most of them are alloys. Therefore, it is very necessary to explore the feasibility of the method in the application of alloys. In the process, in order to protect shape of micro-hole, metal wires coated with graphite paint are selected as the hole cores. Aiming at demonstrating the quality of array micro-holes, the aspect ratio, roughness and roundness of array micro-holes are researched. The results show that the casting process of micro-holes is suitable for ZL102 alloy, and the roughness and the shape factor of micro-hole is 6.85 μm and 0.98. The silicon element in the alloy is ability of reducing viscosity and surface tension of melt molten, which is improving filling ability of melt molten. So, parameters of micro-hole, including aspect ratio, roughness and roundness, are better than that of pure aluminum.

     

Application of Monte Carlo simulation for estimation of uncertainty of four-point roundness measurements of rolls

Large-scale rotors in the paper and steel industry are called rolls. Rolls are reground at regular intervals and roundness measurements are made throughout the machining process. Measurement systems for roundness and diameter variation of large rolls (diameter <2000 mm) are available on the market, and generally use two to four sensors and a roundness measurement algorithm. These methods are intended to separate roundness of the rotor from its movement. The hybrid four-point method has improved accuracy, even for harmonic component amplitudes. For reliable measurement results, every measurement should be traceable with an estimation of measurement uncertainty. In this paper, the Monte-Carlo method is used for uncertainty evaluation of the harmonic components of the measured roundness profile under typical industrial conditions. According to the evaluation, the standard uncertainties for the harmonic amplitudes with the hybrid method are below 0.5 μm for the even harmonics and from 1.5 μm to 2.5 μm for the odd harmonics, when the standard uncertainty for the four probes is 0.3 μm each. The standard uncertainty for roundness deviation is 3.3 μm.