复杂结构的钛合金宽弦空心风扇叶片的双层制造工艺及其毛坯优化设计（英文）

Two-Layer Process and Optimal Blank Design for Hollow Titanium Wide-Chord Fan Blades with Complex Geometries

钛合金宽弦空心风扇叶片是航空发动机的重要部件,具有复杂的结构特点,内部交替排列减重空腔与加强筋,采用基于复杂超塑性成形的传统多层工艺成形难度大。针对以上问题,提出一种基于热成形和扩散连接技术的新双层制造工艺,并且规划了一条毛坯优化设计的基本技术途径,更可靠可控的构建了内部加强筋。借用ABAQUS软件数值模拟成形,分析成形结果的厚度均匀性、结构完整性和表面缺陷,以及评估方法的实用性。以Ti-6Al-4V为成形材料,采用经尺寸优化后的最佳坯料,进行了一系列的实验来验证仿真结果。实验成功制造出无缺陷的缩比版钛合金宽弦空心风扇叶片,同时实验与仿真模拟结果非常吻合。

A new two-layer process based on hot forming and diffusion bonding for forming a hollow titanium wide-chord fan blade with complex geometries was developed. An essential approach for optimal blank design was proposed. The present process employed a more reliable and controllable method to construct the internal ribbons, instead of complicated superplastic forming. To evaluate the practicability, a numerical method was used to investigate the thickness uniformity, structural integrity and skin defects of forming results using ABAQUS. A series of experiments were conducted to validate the simulation results. The Ti-6 Al-4 V alloy was adopted as the forming material, and blanks optimized by the proposed approach were used. The results show that a scaled-down version of the hollow wide-chord fan blade without defects is successfully formed. In addition, it is observed that the experimentation and simulation agree well.