燃气轮机压气机叶片精密挤压成形新工艺及关键装备设计

New Technology and Key Equipment Design of Precision Extrusion Forming for Gas Turbine Compressor Blades

针对当前燃气轮机压气机叶片传统的多工序精锻工艺存在的不足,提出一种以纵向挤压为主要技术特征的叶片精密挤压成形新工艺,将坯料的塑性加工过程分成压扁、叶身挤压和挤压榫头3个工序。以某型燃气轮机第5级压气机悬臂静子叶片为研究对象,基于有限元模拟软件DEFORM-3D,对采用新工艺的叶片挤压成形过程进行了数值模拟,获得了金属的流动状态和各工序中应力、应变的分布特性及载荷的变化规律。根据新工艺的技术特点,确定叶身挤压是新工艺中的关键工序并为其提出相应的工艺装备设计方案。与传统工艺相比,该叶片成形新工艺有利于实现短流程、高材料利用率、低制造成本的精密快捷制造,可为促进压气机叶片生产技术的升级换代提供有价值的参考。

Aiming at the shortcomings of the traditional multi-process precision forging process for gas turbine compressor blades,a new precision extrusion process for manufacturing blades with longitudinal extrusion as the main technical feature is proposed.The plastic processing process of the process is divided into three processes:flattening,blade body extrusion and tenon extrusion.For the cantilever stator blade of the 5th stage compressor of a gas turbine,based on the finite element simulation software DEFORM-3D,its forming process is simulated by the proposed new technology,and the flow state of metal as well as the distribution characteristics of effective stress filed,effective strain field,effective strain field and the change rule of load in each station are obtained.According to the technical characteristics of the new process,it is pointed out that blade extrusion is the key link in the new process,and the corresponding process equipment design scheme is put forward.Compared with the traditional technology,the new blade forming technology proposed is conducive to the accurate and fast manufacturing with short process,high material utilization rate and low manufacturing cost,and can provide a valuable reference for promoting the upgrading of compressor blade production technology.