航空发动机叶片导流管的固态介质模锻成形技术

Solid Medium Forging of Impingement Cooling Pipe for Aero-Engine Blade

对导流管的固态介质模锻成形工艺过程进行了有限元仿真,并对管坯尺寸、芯料体积、管坯与芯料和模具的摩擦系数等工艺参数展开研究,得到该工艺各参数对管坯成形后的厚度分布和形状精度的影响规律。分别通过单向拉伸试验和单向压缩试验,得到管坯材料和固态介质锡的应力–应变关系。给出了以零件最终几何信息来确定管坯和芯料几何尺寸的方法。为了避免飞边的出现,提出了沿切向设置分模面的模具设计方式。依据材料数据、管坯、芯料和模具的几何模型,建立了成形过程的有限元模型并对工艺过程进行仿真。将仿真结果中的零件厚度分布和贴模度作为评价成形质量的指标,分析了管坯和芯料的尺寸参数α和β,以及管坯与芯料、模具的摩擦系数fi和ft对成形结果的影响规律。结果表明,管坯和芯料的周长和容积缩放系数组合为α=1.00和β=1.05,摩擦系数组合为fi=0.05和ft=0.05时更有利于成形结果的厚度和贴模度分布。

The pipe die forging with solid-medium-filling was simulated by finite element method to the effects of parameters,such as blank size,core volume and friction coefficients,on the thickness distribution and shape accuracy.The stress–strain cures of tube blank material and core material were obtained by unidirectional tensile test and unidirectional compression test.The methods of determining the geometric dimensions of tube blank and core based on the final parts were given.The tangential parting surface was proposed in die design in order to avoid flash.According to the material data,the geometric model of tube blank,core and die,the finite element model of forming process was established.Then the processing was simulated.Taking the part thickness distribution and the gap between part and die in the simulation results as the indexes to evaluate the forming quality,the effects of the dimensional parameters ofαandβand the friction coefficients f_(i) and f_(t) on the forming results are analyzed.The results show that the dimensional parameter combination α=1.00 and β=1.05 and the friction coefficient combination f_(i)=0.05 and f_(t)=0.05 are more conducive to the thickness distribution and shape accuracy.