增材制造技术在涡轮叶片减振改进中的优势

G. Moneta, Michal Fedasz, Michał Szmidt, Sławomir Cieślak, W. Krzymień
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引用次数: 1

摘要

经典涡轮叶片设计理念假定所谓的无共振动态解决方案(避免共振的特征转速)实现特征频率调谐。为了满足当前的市场需求,现代发动机需要:在更高的负载下运行,在更高的燃烧温度下运行,更快、更频繁地启动和关闭。因此,在变转速和变热条件下,必须更多地将旋转叶片设计为防共振部件。涡轮发动机一个世纪的发展历程为提高叶片的高周疲劳寿命提供了许多解决方案。其中之一是通过零件的先进设计来优化阻尼。在叶片振动过程中有几种主要的阻尼机制:材料阻尼、空气动力阻尼(通常低于0.3%)和摩擦阻尼(取决于设计)。如今,增材制造(AM),特别是激光粉末床融合(LPBF)可以制造具有高结构完整性和延长使用寿命的多功能复杂部件。本文以喷气发动机非冷却涡轮叶片设计为例进行了研究。两种设计已经建模和制造使用LPBF技术:一个基线设计(“固体叶片”)和一个新的设计,其中翼型是充满了一个矩阵的口袋与别针和格子棒包围的非熔融粉末(“格子叶片”)。然后,使用电动激振器测试对两种设计的阻尼比进行了评估,并通过激光振动计测量了响应。除了基线设计中出现的材料阻尼外,新的精密设计还增加了额外的阻尼机制:波通过不同介质传播(波的传播速度变化、波的反射),能量在未熔合的金属粉末中耗散(粉末颗粒之间的摩擦),袋内的实心销钉独立振动(起到动力阻尼作用,改善粉末中的能量耗散),袋内的晶格条将振动波传递给粉末(激活未熔合粉末整体的能量耗散)。激振器试验结果表明,本研究中所有研究模式的阻尼比都显著增加,与摩擦平台下阻尼器和阻尼螺栓等阻尼特性相当。此外,LPBF方法具有多功能的特点——除了显著改善阻尼比外,质量可以减小(在本例中减少约6%),特征频率可以调谐以避免共振,应力集中因子可以减小(这是下一步研究的计划),等等。到目前为止,提出的新设计尚未进行优化,因此阻尼性能的进一步改进余地很大。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Advantages of Additive Manufacturing Technology in Damping Improvement of Turbine Blading
Classical turbine blade design philosophy assumes so-called resonance-free dynamic solution (avoiding resonances for characteristic rotational speeds) achieved by eigenfrequency tunning. To meet current market demands, modern engines need: to operate with higher load, operate at higher firing temperatures, to startup and shutdown faster and more frequently. Therefore, the rotating blade must be more often designed as the resonance-proof component under circumstances of the variable rotational speed and varying thermal conditions. A century of turbine engine development has provided many solutions for improvement of High Cycle Fatigue lifetime of the blading. One of them is damping optimization through advanced design of parts. There are few main damping mechanisms occurring during blade vibrations: material damping, aerodynamical damping (usually below 0.3%) and frictional damping (depending on the design). Nowadays, the Additive Manufacturing (AM) and especially Laser Powder Bed Fusion (LPBF) allow to manufacture multifunctional and complex components with high structural integrity and extended lifetime. An example of uncooled turbine blade design of a jet engine has been studied. Two designs have been modelled and manufactured using LPBF technology: a baseline design (‘Solid Blade’) and a new design where the airfoil was filled with a matrix of pockets with pins and lattice bars surrounded by non-fused powder (‘Lattice Blade’). Then, the damping ratio has been assessed for both designs using electrodynamic shaker tests — the response was measured by laser vibrometer. Except material damping occurring in the baseline design, the new sophisticated design has additional damping mechanisms: the wave propagates through different media (changes of wave propagation speed, wave reflections), energy dissipates in the non-fused metal powder (friction between powder particles), solid pins in the pockets vibrate independently (act as dynamic dampers and improve energy dissipation in the powder), lattice bars in the pockets transfer the vibration wave to the powder (activate energy dissipation in the whole volume of the non-fused powder). The results of shaker tests show significant damping ratio increase for all investigated modes in this study — comparable to such damping features like friction under-platform dampers and damping bolts. Additionally, the LPBF approach has a multi-functional character — except significant improvement of damping ratio, the mass can be reduced (in this case decreased by about 6%), eigenfrequency can be tuned to avoid resonance, the stress concentration factors can be reduced (which is planned for next studies), etc. The proposed new design has not been optimized so far, giving wide margin for further improvements of the damping performance.
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