Turbine Blade Investment Casting Die Technology

250 Pages·2017·10.61 MB·English

by  Bu

Dinghua Zhang · Yunyong Cheng
Ruisong Jiang · Neng Wan
Turbine Blade
Investment
Casting Die
Technology
Translated by Kuidong Huang,
Wenhu Wang and Kun Bu
Turbine Blade Investment Casting Die Technology
Dinghua Zhang Yunyong Cheng
(cid:129)
Ruisong Jiang Neng Wan
(cid:129)
Turbine Blade Investment
Casting Die Technology
123
Authors Translated by
Dinghua Zhang Kuidong Huang
Northwestern Polytechnical University Northwestern Polytechnical University
Xi’an Xi’an
China China
Yunyong Cheng WenhuWang
Northwestern Polytechnical University Northwestern Polytechnical University
Xi’an Xi’an
China China
RuisongJiang KunBu
Northwestern Polytechnical University Northwestern Polytechnical University
Xi’an Xi’an
China China
Neng Wan
Northwestern Polytechnical University
Xi’an
China
ISBN978-3-662-54186-9 ISBN978-3-662-54188-3 (eBook)
DOI 10.1007/978-3-662-54188-3
JointlypublishedwithNationalDefenseIndustryPress,Beijing,China
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Preface
As the key component of aero-engine, turbine blades determine the performance,
reliability and security of the aero-engine. Due to the high external dimensional
accuracy,andcomplicatedinternalcoolingchannelsofturbineblades,whichmake
the fabrication of such blades more difficult. Hollow turbine blade manufacturing
technology has become a major issue during the development of aero-engine.
Currently, turbine blades are fabricated by using investment casting process and
then supplement the necessary machining process. Among those processes, die
cavity optimization, precision manufacturing, and rapid leading are the key points
to ensure the accuracy, and shorten the manufacturing period for turbine blades.
The Key Laboratory of Contemporary Design and Integrated Manufacturing
Technology, Ministry of Education in Northwestern Polytechnical University has
carried out research on the design, analysis, and manufacturing technologies of
investment casting die for complex hollow turbine blades. Funded by National
High-tech R&D Program, National Key Technologies R&D Program,
Aero-Science Foundation of China, the integrated design and manufacturing
technologiesofinvestmentcastingdiewerewidelystudied,andover100academic
papers were published. Independently developed “turbine blade casting die
CAD/CAM system” won the 1999 annual ministerial level scientific and techno-
logical progress award.
Thetheoryandapplicationachievementsinthefieldofturbinebladecastingdie
were summarized systematically in this book. The related materials have been
mainly from the group of “Advanced manufacturing technologies for aero-engine”
led by Prof. Dinghua Zhang since 1990s, including academic research papers,
technical reports, and patent literature. The main contents include digital modeling
of turbine blades, casting die design, cavity optimization, precision manufacturing
ofdieandrapidleading,anddetectionandevaluationtechnologyforturbineblade.
This book aims to provide advanced digital casting die design theory, method and
practical technical reference for engineering practice.
The current Ph.D. and graduated students in our group has provided a large
number of pictures and materials. In addition, Xi'an Aero Engine Co., Ltd., China
Gas Turbine Establishment, Beijing Institute of Aeronautical Materials, and other
v
vi Preface
structures also provide a lot of support. The book was funded by the National
DefenseScienceandTechnologypublishedFund.Theauthorssincerelyappreciate
the support mentioned above.
ThisbookwasconceivedbyProf.DinghuaZhang,andcheckedbyProf.Wenhu
Wang. This book consists of seven chapters, Chaps. 1 and 6 were written by
DinghuaZhang;Chap.2waswrittenbyNengWan;Chaps.3and4werewrittenby
Wenhu Wang and Ruisong Jiang; Chap. 5 was written by Kun Bu and Yunyong
Cheng; and Chap. 7 was written by Yunyong Cheng and Kuidong Huang.
Because oftheourlimitedknowledge,mistakescannot beavoidedinthebook.
Please feel free to contact us and point out the mistakes.
Xi’an, China Dinghua Zhang
Yunyong Cheng
Ruisong Jiang
Neng Wan
Contents
1 Introduction.... .... .... ..... .... .... .... .... .... ..... .... 1
1.1 Turbine Blade of Aero-Engine... .... .... .... .... ..... .... 1
1.1.1 Introduction of Aero-Engine... .... .... .... ..... .... 1
1.1.2 Turbine Blade of Aero-Engine . .... .... .... ..... .... 3
1.2 Investment Casting Process of Turbine Blade.... .... ..... .... 7
1.2.1 The Main Processes of Investment Casting.... ..... .... 7
1.2.2 Main Issues in Investment Casting of Turbine Blade . .... 8
1.3 Literature Review of Investment Casting Die Technology ... .... 9
1.3.1 Parametric Modeling for Turbine Blade .. .... ..... .... 9
1.3.2 Intelligent Design for Investment Casting Die.. ..... .... 10
1.3.3 Optimization of Investment Casting Die Cavity ..... .... 13
1.3.4 NDT of Investment Casting Blade
and Rapid Finalization ... .... .... .... .... ..... .... 14
1.4 The Developmental Trends in Turbine Blade Investment
Casting Technology .. ..... .... .... .... .... .... ..... .... 16
References.. .... .... .... ..... .... .... .... .... .... ..... .... 18
2 Digitized Modeling Technology of Turbine Blade... .... ..... .... 21
2.1 Structural Features Classification of Turbine Blade ... ..... .... 21
2.1.1 Structural Elements Classification of Turbine Blade .. .... 21
2.1.2 Feature Modeling ... .... .... .... .... .... ..... .... 24
2.1.3 Feature Definitions of Turbine Blade Structure. ..... .... 25
2.2 Parametric Modeling of Structural Features . .... .... ..... .... 27
2.2.1 Design Process of Turbine Blade ... .... .... ..... .... 27
2.2.2 Basic Principle of Parametric Modeling .. .... ..... .... 28
2.2.3 Datum Feature of Turbine Blade Modeling.... ..... .... 31
2.2.4 Surface Modeling of Turbine Blade . .... .... ..... .... 32
2.2.5 Internal Profile Feature Modeling of Turbine Blade .. .... 44
2.2.6 Typical Feature Modeling. .... .... .... .... ..... .... 50
vii
viii Contents
2.3 Case Study. .... .... ..... .... .... .... .... .... ..... .... 60
References.. .... .... .... ..... .... .... .... .... .... ..... .... 61
3 Cavity Design Method for Investment Casting Die of Turbine
Blade . .... .... .... .... ..... .... .... .... .... .... ..... .... 63
3.1 Multistate Model Transformation Method for Investment
Casting Die Cavity of Turbine Blade.. .... .... .... ..... .... 63
3.1.1 Definition of Multistate Model of Investment Casting
Die Cavity.... ..... .... .... .... .... .... ..... .... 64
3.1.2 Investment Casting Process Driven Multistate Model
Transformation ..... .... .... .... .... .... ..... .... 65
3.1.3 Geometric Information Mapping for Multistate Model
Based on Rules..... .... .... .... .... .... ..... .... 67
3.2 Parting Technologies for Investment Casting Die Cavity .... .... 74
3.2.1 The Parting Principle Based on Feature Decomposition ... 75
3.2.2 The Die Cavity Feature Decomposition Method..... .... 76
3.2.3 Rule-Based Parting Method of Die Cavity .... ..... .... 78
3.3 Design Examples of Investment Casting Die Cavity... ..... .... 82
References.. .... .... .... ..... .... .... .... .... .... ..... .... 83
4 Design of the Die Base for the Investment Casting Turbine
Blade . .... .... .... .... ..... .... .... .... .... .... ..... .... 85
4.1 Definition and Structure of the Knowledge Template
of Die Base .... .... ..... .... .... .... .... .... ..... .... 87
4.1.1 Typical Structure of the Base of the Investment
Casting Die... ..... .... .... .... .... .... ..... .... 87
4.1.2 The Definition of the Knowledge Template
for the Die Base .... .... .... .... .... .... ..... .... 88
4.1.3 Structure and Data Model of the Knowledge Template
for the Die Base .... .... .... .... .... .... ..... .... 91
4.2 The Method to Construct a Knowledge Template
for Investment Casting Die.. .... .... .... .... .... ..... .... 94
4.2.1 The Procedures to Construct a Knowledge Template
for the Die Base .... .... .... .... .... .... ..... .... 94
4.2.2 Extraction of the Knowledge Template... .... ..... .... 95
4.2.3 Customization of the Knowledge Template
for the Die Base .... .... .... .... .... .... ..... .... 98
4.3 Rapid Design of Investment Casting Die Base Based
on the Knowledge Template. .... .... .... .... .... ..... .... 101
4.3.1 Rapid Design Method of the Die Base... .... ..... .... 101
4.3.2 Design Example with the Template.. .... .... ..... .... 103
References.. .... .... .... ..... .... .... .... .... .... ..... .... 104
Contents ix
5 Deformation Simulation of Investment Casting and Die Cavity
Optimization of Turbine Blade.. .... .... .... .... .... ..... .... 105
5.1 Deformation Simulation of Turbine Blade Investment
Casting.... .... .... ..... .... .... .... .... .... ..... .... 105
5.1.1 Investment Casting Simulation Modeling . .... ..... .... 105
5.1.2 Finite Element Modeling Investment Casting .. ..... .... 112
5.1.3 Investment Casting Simulation . .... .... .... ..... .... 115
5.2 The Analysis Calculation of the Simulation of Investment
Casting Deformation.. ..... .... .... .... .... .... ..... .... 134
5.2.1 The Distribution Regularity of Turbine Blade Surface
Size Errors ... ..... .... .... .... .... .... ..... .... 134
5.2.2 The Definition of the Displacement Field
of Solidification Process .. .... .... .... .... ..... .... 135
5.2.3 The Calculate Method of Displacement Field.. ..... .... 136
5.2.4 Vector Expression and Vector Resolution of the
Displacement Field.. .... .... .... .... .... ..... .... 136
5.2.5 The Establishment of Displacement Field Model .... .... 141
5.3 Reserve Deformation Optimization and Virtual Mold Repair
of the Mold Cavity... ..... .... .... .... .... .... ..... .... 142
5.3.1 Calculating Methods of Cavity Size . .... .... ..... .... 142
5.3.2 The Method of Reverse Deformation of Cavity ..... .... 146
5.3.3 Reverse Superposition Method of Grid Displacement
Field .... .... ..... .... .... .... .... .... ..... .... 151
5.3.4 Cavity Optimization Based on Superimposed
Displacement Field.. .... .... .... .... .... ..... .... 152
5.3.5 Scaling Method Based on Shrinkage Ratio.... ..... .... 156
5.4 The Rapid Verification Technologies of Cavity Optimization. .... 166
5.4.1 Die Cavity Validation Scheme Based on Wax
Pattern NC Machining ... .... .... .... .... ..... .... 166
5.4.2 Wax Material Craft Process and Machining Parameter
Optimization.. ..... .... .... .... .... .... ..... .... 168
5.4.3 NC Machining Post Processing of Wax Material .... .... 169
References.. .... .... .... ..... .... .... .... .... .... ..... .... 169
6 The Manufacturing and Finalization of the Turbine Blade
Investment Casting Die... ..... .... .... .... .... .... ..... .... 173
6.1 The Manufacturing Process of the Turbine Blade Investment
Casting Die. .... .... ..... .... .... .... .... .... ..... .... 173
6.1.1 The Structural Features of the Turbine Blade Investment
Casting Die... ..... .... .... .... .... .... ..... .... 173
6.1.2 The Manufacturing Process of the Turbine Blade
Investment Casting Die... .... .... .... .... ..... .... 174
x Contents
6.2 The Process Plan of the Turbine Blade Investment
Casting Die. .... .... ..... .... .... .... .... .... ..... .... 176
6.2.1 Materials Selection for Die Manufacturing .... ..... .... 176
6.2.2 The Process Planning for Die Manufacturing .. ..... .... 178
6.2.3 The Design of the Second Tooling Electrode .. ..... .... 182
6.2.4 The Selection of the Process Ball... .... .... ..... .... 185
6.3 The Machining Technology of the Turbine Blade Investment
Casting Die. .... .... ..... .... .... .... .... .... ..... .... 185
6.3.1 The Machining Technology ... .... .... .... ..... .... 185
6.3.2 Nontraditional Machining Technologies in Die
Manufacturing. ..... .... .... .... .... .... ..... .... 188
6.3.3 The Surface Treatment Technology.. .... .... ..... .... 198
6.3.4 The Repairing Technique . .... .... .... .... ..... .... 204
6.4 The Finalization of the Turbine Blade Investment
Casting Die. .... .... ..... .... .... .... .... .... ..... .... 206
6.4.1 The Inspection of the Investment Casting Die.. ..... .... 206
6.4.2 The Testing of the Investment Casting Die.... ..... .... 207
6.4.3 The Finalization of the Investment Casting Die ..... .... 208
References.. .... .... .... ..... .... .... .... .... .... ..... .... 209
7 Turbine Blade Investment Casting Experiment and Measurement
Evaluation . .... .... .... ..... .... .... .... .... .... ..... .... 211
7.1 Investment Casting Experiment Process.... .... .... ..... .... 211
7.2 Blade Casting Geometrical Dimension Measurement and
Evaluation.. .... .... ..... .... .... .... .... .... ..... .... 212
7.2.1 Measurement Data Acquisition. .... .... .... ..... .... 213
7.2.2 Model Alignment ... .... .... .... .... .... ..... .... 227
7.2.3 Geometrical Shape Analysis ... .... .... .... ..... .... 234
References.. .... .... .... ..... .... .... .... .... .... ..... .... 241