Abrasive flow finishing characteristics of internal cooling channel of turbine blade
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摘要: 航空涡轮叶片内部的多冷却通道多采用消失模铸造等方法制造，其表面粗糙度较高，冷却效率低，内部流道截面小且呈S形弯曲狭长分布，不容易抛光。用Polyflow软件对叶片内冷通道进行仿真，研究其内部压力场、速度场的变化情况。在工件的4个典型区域进行S形内流道加工试验，研究表面粗糙度与材料去除量的变化规律。结果表明：经仿真，压力下降的幅度沿流动方向逐渐变小，速度由通道中心向壁面逐渐减小；相同试验条件下，S形流道转弯处的表面粗糙度比直流道处的低；流道内存在沿程压力损失，区域A比区域D的材料去除量大4～5倍。
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关键词:
- 磨料流加工 /
- 涡轮叶片 /
- S形流道 /
- Polyflow仿真模拟 /
- 内冷通道
Abstract: The internal multi cooling channels of aviation turbine blades, mostly processed by lost foam casting, have high surface roughness, low cooling efficiency, small internal channel section and S-shaped bending and narrow distribution, and are not easy to polish. The Polyflow software is used to simulate the internal cooling channel of blade, and the changes of internal pressure field and velocity field are studied. The workpiece with S-shaped inner runner was machined and tested to study the variation law of surface roughness and material removal in four typical areas of the workpiece. The results show that the pressure drop decreases along the flow direction and the velocity decreases from the center of the channel to the wall; under the same test conditions, the surface roughness at the turning of S-shaped channel is lower than that at the straight channel; there is pressure loss along the flow path, and the material removal in area A is 4～5 times greater than that in area D. -
图 4 工件壁面处磨粒的微切削过程
Figure 4. Microcutting process of abrasive particles on workpiece wall surface
图 5 S形流道模型与流道网格划分
Figure 5. S-shaped flow channel model and flow channel mesh division
图 10 表面粗糙度测量点分布区域
Figure 10. Distribution area of surface roughness measurement points
图 11 Q235工件加工前后表面粗糙度
Figure 11. Surface roughness of Q235 workpiece before and after machining
图 13 45钢工件加工前后表面粗糙度
Figure 13. Surface roughness of 45 steel workpiece before and after machining
图 15 2种工件3次加工后的材料去除量
Figure 15. Material removal of two workpiece after three treatments
表 1 流场网格划分数据
Table 1. Flow field meshing data
类型 最小尺寸a / m 最大尺寸b / m 单元数 节点数 平均网格质量 数值 3.415×10−5 6.831×10-3 27 772 34 650 0.928 67 
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表 2 试验方案
Table 2. Test scheme
编号 材料 加工次数 磨料粒度尺寸 d / mm 磨粒质量分数 ω / % 1 Q235 3 0.15 30 2 45钢 3 0.15 30 3 45钢 6 0.15 30
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