航空发动机叶片疲劳的损伤力学研究及外物损伤影响
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摘要
现代运输和国防需求,促进了民用和军用飞机的快速发展。随着航空工业的快速发展,对燃气涡轮发动机的性能和安全可靠性提出了越来越高的要求。然而,伴随性能的提高,发动机零部件的工作条件更加严峻、恶劣、应力水平更高,从而使结构完整性,安全可靠性成为制约发动机发展的突出问题。
叶片是航空发动机的主要零件之一,其结构和承载状况复杂,特别是转子叶片,薄而长,不仅在高速旋转,且转速多变,并受到气流和燃气的冲击发生振动,位于发动机前部的压气机叶片还可能受到被吸入的砂、石等外物撞击作用。这种转速变化引起的低循环交变应力和高速转动中气流激振导致的高频振动应力,使叶片逐渐损伤,发生故障直至疲劳破坏,叶片的疲劳掉块与折断可能将压气机甚至整台发动机打坏,造成飞机失事,这样的例子时有发生,后果严重。
研究叶片高低周疲劳损伤规律,改进疲劳分析方法提高疲劳损伤评估和寿命预测水平,是航空发动机结构完整性和可靠性研究的基础和重要组成部分。本文基于连续损伤力学理论和疲劳损伤试验,系统地分析和研究了转子叶片在低循环和高循环载荷作用下疲劳损伤问题,并发展了一个完整的压气机转子叶片疲劳损伤力学有限元分析系统,为叶片疲劳研究提供了一个新的途径。此外,对严重影响叶片寿命的外物损伤及其对高周疲劳的影响进行了试验研究和数值分析。本文的主要内容如下：
(1)叶片低周疲劳损伤力学模型和分析方法研究。利用已有的观测结果,从疲劳机理方面讨论了损伤力学分析的合理性和优点,根据本文的应变疲劳试验测试,改进了常用的低周疲劳损伤模型,使模型描述的损伤演化规律与试验结果在整个疲劳损伤过程中符合较好。根据钛合金TC4材料低循环损伤演化特点,提出低周疲劳损伤演化分析和寿命预测的简化分析方法,以及通过模拟试件的反演分析研究损伤材料常数的实用方法。
(2)叶片高周疲劳损伤力学模型和分析方法研究。根据高周疲劳损伤机理,推导高周疲劳损伤演化方程,将低周疲劳损伤分析中提出的方法,推广应用于振动应力引起的高周疲劳。
(3)对于压气机叶片常用材料TC4标准试件,在4种不同应变幅值下进行应变疲劳损伤的试验观测,得到应变软化、损伤发展和疲劳破坏过程特点,以及滞后回线变化规律和极限损伤变量,为损伤模型和分析方法研究及数值计算提供试验数据和基本参数。
(4)叶片高、低周疲劳损伤力学分析软件系统。为了给本文研究和实际应用提供分析手段和研究平台,利用三维20节点六面体等参单元,自编了一个叶片疲劳损伤力学有限元分析软件系统(Fortran语言,约10000句),具有准静态弹塑性分析、振动特性和响应分析、低周和高周疲劳损伤演化分析及寿命预测等功能和较好的前后处理。提出了适用于叶片疲劳分析的循环弹塑性应力、振动应力和损伤演化计算方法,对程序进行了全面考核。
(5)典型叶片的疲劳损伤分析。利用上述模型、方法和软件,对于典型的实际压气机叶片进行了系列分析,包括给定载荷谱块下的循环弹塑性应力、动频和静频、振动应力、疲劳损伤场和演化以及疲劳寿命,对结果和变化规律进行了分析讨论。实际算例证明了本文改进的损伤模型,提出的简化分析方法和开发的专用软件是有效的。
(6)叶片前缘的外物损伤及对高周疲劳影响研究。用自制自由落体冲击试验装置进行模拟叶片前缘落锤冲击试验,模拟硬物颗粒撞冲前缘引起的损伤,得到冲击能量与缺口深度的关系。在不同循环应力幅值下,对冲击后试件进行了应力疲劳试验,并对外物损伤模拟和疲劳寿命再分析,给出剩余寿命随应力幅值的变化规律。
With the requirements of modern transport and national defense, civil and military aircraft are rapidly developing and the performance, reliability and safety of gas turbine engine will become higher and higher. The increase of thrust weight ratio, as a key measure of engine performance, is obtained from the applications of new materials, structures, advanced manufacture method etc, and so the properties of material are improved and working stress margins are reduced, at same time, the operation condition of engine components/parts becomes much more serious or deteriorative and its stress level is higher, thus structural integrity, safety and reliability become a key restraining the fast development of engine.
Blade is major parts of aircraft engine. The blades, especially rotor blades, are complicated in structure and loading. thin and long in size, work in high and variable rotation speed, and are subject to impact of air and gas flow that can result in vibration. Compressor blades located in front of engine may also be damaged by the impact of sand, stone and other foreign objects ingested into engine. Low cycle stress caused by the variable rotating speed and the high cycle stress from high frequency vibration excited by unsteady flow make blade damaged increasingly, until fatigue failure occurs. The blade fracture may break compressor or whole engine, furthermore lead to aircraft accident.
It is the one of the major objectives and important part of air engine structural integrity and reliability to study the law of high and low cycle fatigue, to refine fatigue analysis method and to improve the level of the fatigue damage assessment and life prediction. In this paper, based on continuum damage mechanics (CDM) and fatigue damage test, fatigue damage of rotor blades under low and high cycle loading was systematically analyzed and studied, a FE program system for whole CDM-analysis for fatigue damage of compressor rotor blades was developed, which provides a new approach to blade fatigue analysis. Furthermore, foreign object damage (FOD) that seriously reduces blade life were investigated through test and numerical modeling. The main researches are as follows:
(1) Investigation of damage mechanics model and analytical method for blade low cycle fatigue.
Using the existing tests results, the rationality and advantages of damage mechanics approach to fatigue analysis were discussed from the short crack mechanism of fatigue. Based on the present strain-controlled fatigue test data, the traditional low cycle fatigue damage model was refined which is good agreement with the test result in all fatigue damage process. A simplified method for damage evolution analysis and life prediction of low cycle fatigue has been developed according to low fatigue damage evolution of titanium alloy Ti-6Al-4V, as well as a convenient inverse analysis to determine the damage parameters of materials.
(2) Investigation of damage mechanics model and analytical method for blade high cycle fatigue.
Based on high cycle fatigue damage mechanism, the damage evolution equation was derived. The proposed method was extended and applied to high cycle fatigue caused by vibration stress.
(3) The strain-controlled fatigue damage test in four strain amplitudes was completed for the standard specimens of the material TC4 used for compressor blade. Characteristics of strain softening, damage growth and fatigue damage process, variation of loop and limit of damage variable were obtained, and the test data and essential parameter is provided for the study of damage model and analysis method, as well as numerical calculation.
(4) FE software system (by Fortran, with 10000 sentences) has been developed for low and high cycle fatigue analysis by damage mechanics.
In order to provide research tools and platform for the study of this paper and application, FE analysis software has been developed for blade fatigue damage mechanics with 3D 20 nodes hexahedron isoperimetric element. The system have the function of elasto-plastic analysis, vibration analysis, low cycle and high cycle fatigue damage evolution analysis, life prediction and better pre-processing and past-processing. The programs has been fully validated.
(5) Fatigue damage analysis for typical blade.
With the above model, method, and programs, A series of analysis was carried out for typical compressor blade, including cycle elasto-plastic stress, dynamic frequency and static frequency, vibration stress, fatigue damage field and fatigue life in given load cycle, and result were discussed. The result show that the refined damage model, the proposed simplified methods and the software are available.
(6) Investigation of foreign object damage(FOD) on blade leading edge and its influence on high cycle fatigue
The connection of the indent depth and impact energy were obtained by impacting on specimens simulating blade leading edge using self-made lift hammer in the free falling body. A combined the stress-controlled fatigue test and numerical analysis was done with the damaged specimens which give the residual life vs stress amplitudes.
叶片是航空发动机的主要零件之一,其结构和承载状况复杂,特别是转子叶片,薄而长,不仅在高速旋转,且转速多变,并受到气流和燃气的冲击发生振动,位于发动机前部的压气机叶片还可能受到被吸入的砂、石等外物撞击作用。这种转速变化引起的低循环交变应力和高速转动中气流激振导致的高频振动应力,使叶片逐渐损伤,发生故障直至疲劳破坏,叶片的疲劳掉块与折断可能将压气机甚至整台发动机打坏,造成飞机失事,这样的例子时有发生,后果严重。
研究叶片高低周疲劳损伤规律,改进疲劳分析方法提高疲劳损伤评估和寿命预测水平,是航空发动机结构完整性和可靠性研究的基础和重要组成部分。本文基于连续损伤力学理论和疲劳损伤试验,系统地分析和研究了转子叶片在低循环和高循环载荷作用下疲劳损伤问题,并发展了一个完整的压气机转子叶片疲劳损伤力学有限元分析系统,为叶片疲劳研究提供了一个新的途径。此外,对严重影响叶片寿命的外物损伤及其对高周疲劳的影响进行了试验研究和数值分析。本文的主要内容如下：
(1)叶片低周疲劳损伤力学模型和分析方法研究。利用已有的观测结果,从疲劳机理方面讨论了损伤力学分析的合理性和优点,根据本文的应变疲劳试验测试,改进了常用的低周疲劳损伤模型,使模型描述的损伤演化规律与试验结果在整个疲劳损伤过程中符合较好。根据钛合金TC4材料低循环损伤演化特点,提出低周疲劳损伤演化分析和寿命预测的简化分析方法,以及通过模拟试件的反演分析研究损伤材料常数的实用方法。
(2)叶片高周疲劳损伤力学模型和分析方法研究。根据高周疲劳损伤机理,推导高周疲劳损伤演化方程,将低周疲劳损伤分析中提出的方法,推广应用于振动应力引起的高周疲劳。
(3)对于压气机叶片常用材料TC4标准试件,在4种不同应变幅值下进行应变疲劳损伤的试验观测,得到应变软化、损伤发展和疲劳破坏过程特点,以及滞后回线变化规律和极限损伤变量,为损伤模型和分析方法研究及数值计算提供试验数据和基本参数。
(4)叶片高、低周疲劳损伤力学分析软件系统。为了给本文研究和实际应用提供分析手段和研究平台,利用三维20节点六面体等参单元,自编了一个叶片疲劳损伤力学有限元分析软件系统(Fortran语言,约10000句),具有准静态弹塑性分析、振动特性和响应分析、低周和高周疲劳损伤演化分析及寿命预测等功能和较好的前后处理。提出了适用于叶片疲劳分析的循环弹塑性应力、振动应力和损伤演化计算方法,对程序进行了全面考核。
(5)典型叶片的疲劳损伤分析。利用上述模型、方法和软件,对于典型的实际压气机叶片进行了系列分析,包括给定载荷谱块下的循环弹塑性应力、动频和静频、振动应力、疲劳损伤场和演化以及疲劳寿命,对结果和变化规律进行了分析讨论。实际算例证明了本文改进的损伤模型,提出的简化分析方法和开发的专用软件是有效的。
(6)叶片前缘的外物损伤及对高周疲劳影响研究。用自制自由落体冲击试验装置进行模拟叶片前缘落锤冲击试验,模拟硬物颗粒撞冲前缘引起的损伤,得到冲击能量与缺口深度的关系。在不同循环应力幅值下,对冲击后试件进行了应力疲劳试验,并对外物损伤模拟和疲劳寿命再分析,给出剩余寿命随应力幅值的变化规律。
With the requirements of modern transport and national defense, civil and military aircraft are rapidly developing and the performance, reliability and safety of gas turbine engine will become higher and higher. The increase of thrust weight ratio, as a key measure of engine performance, is obtained from the applications of new materials, structures, advanced manufacture method etc, and so the properties of material are improved and working stress margins are reduced, at same time, the operation condition of engine components/parts becomes much more serious or deteriorative and its stress level is higher, thus structural integrity, safety and reliability become a key restraining the fast development of engine.
Blade is major parts of aircraft engine. The blades, especially rotor blades, are complicated in structure and loading. thin and long in size, work in high and variable rotation speed, and are subject to impact of air and gas flow that can result in vibration. Compressor blades located in front of engine may also be damaged by the impact of sand, stone and other foreign objects ingested into engine. Low cycle stress caused by the variable rotating speed and the high cycle stress from high frequency vibration excited by unsteady flow make blade damaged increasingly, until fatigue failure occurs. The blade fracture may break compressor or whole engine, furthermore lead to aircraft accident.
It is the one of the major objectives and important part of air engine structural integrity and reliability to study the law of high and low cycle fatigue, to refine fatigue analysis method and to improve the level of the fatigue damage assessment and life prediction. In this paper, based on continuum damage mechanics (CDM) and fatigue damage test, fatigue damage of rotor blades under low and high cycle loading was systematically analyzed and studied, a FE program system for whole CDM-analysis for fatigue damage of compressor rotor blades was developed, which provides a new approach to blade fatigue analysis. Furthermore, foreign object damage (FOD) that seriously reduces blade life were investigated through test and numerical modeling. The main researches are as follows:
(1) Investigation of damage mechanics model and analytical method for blade low cycle fatigue.
Using the existing tests results, the rationality and advantages of damage mechanics approach to fatigue analysis were discussed from the short crack mechanism of fatigue. Based on the present strain-controlled fatigue test data, the traditional low cycle fatigue damage model was refined which is good agreement with the test result in all fatigue damage process. A simplified method for damage evolution analysis and life prediction of low cycle fatigue has been developed according to low fatigue damage evolution of titanium alloy Ti-6Al-4V, as well as a convenient inverse analysis to determine the damage parameters of materials.
(2) Investigation of damage mechanics model and analytical method for blade high cycle fatigue.
Based on high cycle fatigue damage mechanism, the damage evolution equation was derived. The proposed method was extended and applied to high cycle fatigue caused by vibration stress.
(3) The strain-controlled fatigue damage test in four strain amplitudes was completed for the standard specimens of the material TC4 used for compressor blade. Characteristics of strain softening, damage growth and fatigue damage process, variation of loop and limit of damage variable were obtained, and the test data and essential parameter is provided for the study of damage model and analysis method, as well as numerical calculation.
(4) FE software system (by Fortran, with 10000 sentences) has been developed for low and high cycle fatigue analysis by damage mechanics.
In order to provide research tools and platform for the study of this paper and application, FE analysis software has been developed for blade fatigue damage mechanics with 3D 20 nodes hexahedron isoperimetric element. The system have the function of elasto-plastic analysis, vibration analysis, low cycle and high cycle fatigue damage evolution analysis, life prediction and better pre-processing and past-processing. The programs has been fully validated.
(5) Fatigue damage analysis for typical blade.
With the above model, method, and programs, A series of analysis was carried out for typical compressor blade, including cycle elasto-plastic stress, dynamic frequency and static frequency, vibration stress, fatigue damage field and fatigue life in given load cycle, and result were discussed. The result show that the refined damage model, the proposed simplified methods and the software are available.
(6) Investigation of foreign object damage(FOD) on blade leading edge and its influence on high cycle fatigue
The connection of the indent depth and impact energy were obtained by impacting on specimens simulating blade leading edge using self-made lift hammer in the free falling body. A combined the stress-controlled fatigue test and numerical analysis was done with the damaged specimens which give the residual life vs stress amplitudes.
引文
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50. 段巍,安利强,徐飞.基于随机有限元——一次二阶矩法的汽轮机叶片可靠度计算,华北电力大学学报,2004,31(3)：104-107
51. 安利强,段巍,徐飞.叶片振动特性分析中的随机力学方法[J],热量透平,2003,32(3)：143-150
52. 江龙平,徐可君,隋育松.叶片振动的灰色可靠性研究[J]，汽轮机技术,2002,44(5)：286-287
53. 陈晓伟等.压气机叶片的静强度可靠性研究,2000,1：9-12
54.南宫自军,汪亮,张铎.Neumann随机有限元法计算涡轮叶片的可靠度[J],推进技术,1998,19(2)：35-37
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73. 吕涛,杨晓华,李年,杜百平,史耀武.2Cr13钢低周疲劳损伤演变规律研究[J],机械强度,1999,21(2)：118-121
74. Chaboche J T, Lesne P M. A non-liner continuous fatigue damage model[J], Fatigue Fract Engng Mater Struct,1998,1(1):1-17
75. 周柏卓,杨士杰.正交各向异性材料粘塑性损伤寿命研究[J],航空发动机,2001,(2)：4-7
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77. 陈凌,蒋家羚.一种新的低周疲劳损伤及试验验证[J],金属学报,2005,42(2)：157-160
78. Sandeep Kumar, Niranjan Roy, Ranjan Ganguli. Monitoring low cycle fatigue damage in turbine blade using vibration characteristics [J], Mechanical Systems and Signal Processing,2007,21:480-501
79. Paepegem W Van, Degrieck J. Simulating damage and permanent strain in composites under in-plane fatigue loading[J], Computers and Structures,2005,83:1930-1942
80. Yangt Xiaohua, Lit Nian, Jint Zhihao, Wang Tiejun. A continuous low cycle fatigue damage model and its application in engineering materials, Int. J. Fatigue,1997,19 (10):687-692
81. Krajcinovic D, Lemaitre J. A continuum Damage Mechnics:Theory and Application. Berlin:Springer Verlag,1987
82. Desmorat R, Kane A, Seyedi M, Sermage J P. Two scale damage model and related numerical issues for thermo-mechanical High Cycle Fatigue[J], European Journal of Mechanics A/Solids,2007
83. Gerber W W. Low and high cycle fatigue a continuum supported by afm observations[J], Acta mater 1998,46 (14):5007-5021
84. Xiao Y C, Li S, Gao Z. A continuum damage mechanics model for high cycle fatigue[J], Int. J. Fatigue,1998,20 (2):503-508
85. Li Z X, Chan T H T, Ko J M. Fatigue damage model for bridge under traffic loading:application made to Tsing Ma Bridge[J], Theoretical and Applied Fracture Mechanics,2001,35:81-91
86. 康继东,陈世煊.压气机叶片外物损伤及其维修性的研究进展[J],燃气涡轮试验与研究,1998,11(1)
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