虚拟修模技术在涡轮叶片模具优化设计中的应用研究

Exploring Reliability and Precision in Mould Optimization Design of Aero-Engine Turbine Blade

为了提高涡轮叶片的成形质量,减少模具的修模次数,提出了一种基于反变形原理的虚拟修模方法。通过使用P ROCAST软件对涡轮叶片铸造过程进行仿真,利用有限元模型计算涡轮叶片的精铸位移场,建立基于位移场的虚拟修模方法,并使用该方法对模具进行优化设计,经涡轮叶片模具设计仿真实验验证,所采用的方法取得了良好的效果,可初步应用于模具的优化设计。

Having failed to find any information in the open literature about achieving reliability and precision in mould optimization design, we have to explore studying and developing such technical knowhow in China ourselves. We present what we believe to be a promising method, the fruit of our painstaking exploration. In the full paper, we explain our promising method in detail. In this abstract, we give only the topics we discuss in the full paper, （1） the process of transforming the CAD model into CAE model; （2） Calculation of displacement field of mould and the simulation of deformation; （3） Compensation for unavoidable deviation from design shape of mould. We performed simulations, which examined, after each iteration, the effectiveness of our compensation, as measured by the deviations in X, Y and Z directions from design shape that still remained. For a certain aero-engine turbine blade, the deviations after the first iteration were 0. 194 366, 0. 054 674 and 0. 453 754, the sum being 0. 515 815. The deviations after the second iteration were 0. 001 802, 0. 002 627 and 0. 002 917, the sum being 0. 004 667. The deviations after the third iteration were 0. 001 249, 0. 001 771 and 0. 001 035, the sum being 0. 002 557. It can be seen that our method converges very quickly and looks promising. The actual application of our method to casting aero-engine turbine blade remains to be done.