航空发动机损伤叶片再制造修复方法与实现

doi:10.7527/S1000-6893.2015.0102

材料工程与机械制造

本期目录 | 过刊浏览 | 高级检索

前一篇 | 后一篇

航空发动机损伤叶片再制造修复方法与实现

王浩¹, 王立文², 王涛³, 丁华鹏³

1. 中国民航大学工程技术训练中心, 天津 300300;
2. 中国民航大学地面特种设备科研基地, 天津 300300;
3. 中国民航大学航空自动化学院, 天津 300300

收稿日期:2015-01-28 修回日期:2015-04-09 出版日期:2016-03-15 发布日期:2015-04-21
通讯作者: 王浩,Tel.:022-24092595,E-mail:hbgdwh@126.com E-mail:hbgdwh@126.com
作者简介:王浩,男,硕士,讲师。主要研究方向:航空发动机深度检测与维修。Tel:022-24092595,E-mail:hbgdwh@126.com;王立文,男,博士,教授,博士生导师。主要研究方向:流体传动、机场地面特种设备。Tel:022-24092885,E-mail:wlw2885@163.com
基金资助:
国家自然科学基金(U1333121);天津市应用基础与前沿技术研究计划(14JCQNJC05000);工信部重大专项(2013ZX04001071);中央高校基本科研业务费专项资金(3122014D12)

Method and implementation of remanufacture and repair of aircraft engine damaged blades

WANG Hao¹, WANG Liwen², WANG Tao³, DING Huapeng³

1. Engineering Technology Training Center, Civil Aviation University of China, Tianjin 300300, China;
2. Ground Special Equipment Science and Research Base, Civil Aviation University of China, Tianjin 300300, China;
3. School of Aviation Automation, Civil Aviation University of China, Tianjin 300300, China

Received:2015-01-28 Revised:2015-04-09 Online:2016-03-15 Published:2015-04-21
Supported by:
National Natural Science Foundation of China(U1333121);Tianjin Research Program of Application Foundation and Advanced Technology(14JCQNJC05000);Ministry of Industry and Information Technology Science and Technology Major Project(2013ZX04001071);The Fundamental Research Funds for the Central Universities(3122014D12)

摘要/Abstract

摘要：

航空发动机叶片长期工作在高温、高压和高速的环境下,极易出现损伤。但是,损伤叶片的再制造修复技术一直被国外垄断,国内航空公司不得不花费大量的资金和时间将受损叶片送往国外维修。针对此问题,提出一种航空发动机损伤叶片再制造修复方法。首先,对损伤叶片进行失效特征分析,评价修复可行性;其次,获取并处理叶片点云数据,提取叶片截面的边界曲线,重建叶片数字化模型,通过布尔运算得到加工目标模型;再次,采用激光熔覆和自适应加工方法,对损伤叶片进行再制造修复;最后,分别对叶片三维数字化模型与实物进行精度检测和误差分析。结果表明,利用该方法建立的叶片数字化模型具有较好的精度和光顺性,再制造修复误差满足发动机维修手册的要求。

关键词: 航空发动机, 损伤叶片, 失效分析, 再制造, 修复

Abstract:

Aircraft engine blades are subject to damage because they are constantly exposed to high temperature, pressure and speed. Since the technology of repairing the damaged blades has been dominated by foreign companies, domestic airlines have to invest a tremendous amount of cost and time in having damaged blades repaired. This paper is to put forward a method in an attempt to remanufacture and repair damaged blades. Firstly, we evaluate the possibility of repairing the damage by analyzing the characteristics of damaged blades. Secondly, we acquire and process the point cloud of broken blades, extract the boundary curve of the blade section, reconstruct the 3D digital models of blades and obtain the 3D object model of blade via Boolean operation. Thirdly, we repair and remanufacture the damaged blades via laser cladding and adaptive machining. Finally, we check the precision of the 3D digital model and perform an error analysis. The results turn out that the proposed 3D digital model is of relatively greater accuracy and smoothness and remanufactured blade can meet the technical requirements prescribed in the aircraft engine maintenance manual.

Key words: aircraft engines, damaged blades, failure analysis, remanufacture, repair

中图分类号:

V590.45

王浩, 王立文, 王涛, 丁华鹏. 航空发动机损伤叶片再制造修复方法与实现[J]. 航空学报, 2016, 37(3): 1036-1048.

WANG Hao, WANG Liwen, WANG Tao, DING Huapeng. Method and implementation of remanufacture and repair of aircraft engine damaged blades[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2016, 37(3): 1036-1048.

参考文献

[1] 段继豪, 史耀耀, 张军锋. 航空发动机叶片柔性抛光技术[J]. 航空学报, 2012, 33(3):573-578. DUAN J H, SHI Y Y, ZHANG J F. Flexible polishing technology for blade of aviation engine[J]. Acta Aeronautica et Astronautica Sinica, 2012, 33(3):573-578(in Chinese).
[2] 赵慧慧, 张广军, 范庆. 基于焊接的多通道单层再制造熔覆组织及性能[J]. 焊接学报, 2011, 32(2):45-48. ZHAO H H, ZHANG G J, FAN Q. Microstructure and performances antes-pass single-layer weld-based remanufacturing component[J]. Transactions of the China Welding Institution, 2011, 32(2):45-48(in Chinese).
[3] 张胜, 侯金保, 李晓红. 大推力航空发动机热端部件损伤修复技术综述[C]//大型飞机关键技术高层论坛论文集. 北京:中国航空学会, 2007:1-6. ZHANG S, HOU J B, LI X H. A review on repairs of hot-end parts in high thrust aero-engines[C]//Proceedings of Key Techniques of Large Airplanes and Seminar of Chinese Aviation Academy. Beijing:Chinese Society of Aeronautics and Astronautics, 2007:1-6(in Chinese).
[4] HUANG H, GONG Z M, CHEN X Q, et al. SMART robotic system for 3D profile turbine vane airfoil repair[J]. International Journal of Advanced Manufacture Technology, 2003, 21(4):275-283.
[5] HUANG H, GONG Z M, CHEN X Q, et al. Robotic grinding and polishing for turbine-vane overhaul[J]. Journal of Materials Processing Technology, 2002, 127(2):140-145.
[6] MOHAGHEGH K, SADEGHI M H, ABDULLAH A. Reverse engineering of turbine blades based on design intent[J]. International Journal of Advanced Manufacturing Technology, 2007, 32(9-10):1009-1020.
[7] MOHAGHEGH K, MOHAMMAD H, ABDULLAH A, et al. Improvement of reverse-engineered turbine blades using construction geometry[J]. International Journal of Advanced Manufacturing Technology, 2010, 49(5-8):675-678.
[8] YILMAZ O, GINDY N, GAO J. A repair and overhaul methodology for aeroengine components[J]. Robotics and Computer-Integrated Manufacturing, 2010, 26(2):190-201.
[9] PIYA C, WILSON J M, MURUGAPPAN S. Virtual repair:Geometric reconstruction for remanufacturing gas turbine blades[C]//Proceedings of the ASME 2011 International Design Engineering Technical Conferences & Computers and Information in Engineering Conference, 2011:1-10.
[10] 张建平. 德国MTU公司民用航空发动机高压涡轮叶片维修技术[J]. 航空制造技术, 2004(10):70-71. ZHANG J P. The maintenance technology of engine's high pressure turbine blades in German company MTU[J]. Aeronautical Manufacturing Technology, 2004(10):70-71(in Chinese).
[11] 关桥. 发动机叶片与部件修复工程中的焊接技术(上)[J]. 航空制造技术, 1993(2):2-12. GUAN Q. The welding technology of engine blades and parts repair engineering[J]. Aeronautical Manufacturing Technology, 1993(2):2-12(in Chinese).
[12] 孙护国, 霍武军. 航空发动机涡轮叶片的修理技术[J]. 航空工程与维修, 2001(6):12-14. SUN H G, HUO W J. Aeroengine turbine blade repair techniques[J]. Aviation Engineering & Maintenance, 2001(6):12-14(in Chinese).
[13] 白瑞金, 张利国. 涡轮叶片修复及其市场分析[J].航空制造技术, 2002(12):37-40. BAI R J, ZHANG L G. Repair of turbine blades and market analysis[J]. Aeronautical Manufacturing Technology, 2002(12):37-40(in Chinese).
[14] 张红影, 李启东, 李文龙. 基于MLS的航空叶片中弧线提取方法[J]. 中国机械工程, 2014, 25(7):959-964. ZHANG H Y, LI Q D, LI W L. An effective extraction method of aviation engine blade's mean camber line based on MLS method[J]. China Mechanical Engineering, 2014, 25(7):959-964(in Chinese).
[15] 李启东, 李文龙, 周莉萍. 一种曲面特征保持的航空叶片点云精简方法[J]. 机械工程学报, 2014, 25(16):2204-2212. LI Q D, LI W L, ZHOU L P. A surface feature-preserving point cloud simplification method for aviation blades[J]. Journal of Mechanical Engineering, 2014, 25(16):2204-2212(in Chinese).
[16] 彭志光. 基于改进凸包算法的叶片型面检测[D]. 武汉:华中科技大学, 2012:24-40. PENG Z G. The blade surface inspection based on the improved convex hull algorithm[D]. Wuhan:Huazhong University of Science and Technology, 2012:24-40(in Chinese).
[17] GAO J, CHEN X, YILMAAZ O, et al. An integrated adaptive repair solution for complex aerospace components through geometry reconstruction[J]. International Journal of Advanced Manufacturing Technology, 2008, 36(11-12):1170-1179.
[18] WU H D, GAO J, LI S. A review of geometric reconstruction algorithm and repairing methodologies for gas turbine components[J]. TELKOMNIKA Indonesian Journal of Electrical Engineering, 2013, 11(3):1609-1618.
[19] 于之靖, 宋四同. 基于逆向工程的航空发动机叶片数字化建模[J]. 机床与液压, 2011, 39(17):122-125. YU Z J, SONG S T. Based on the reverse engineering of digital model aircraft engine blades[J]. Machine Tool & Hydraulics, 2011, 39(17):122-125(in Chinese).
[20] 赵娜, 李亮玉, 刘杰. 飞机叶片焊接修复中的三维测量重构技术[J]. 焊接学报, 2014, 35(6):73-76. ZHAO N, LI L Y, LIU J. Based on the reverse engineering of digital model aircraft engine blades[J]. Transactions of the China Welding Institution, 2014, 35(6):73-76(in Chinese).
[21] RONG Y, XU J T, SUN Y W. A surface reconstruction strategy based on deformable template for repairing damaged turbine blades[J]. Journal of Aerospace Engineering, 2014, 228(12):2359-2369.
[22] 陶春虎, 钟培道. 航空发动机转动部件的失效与预防[M]. 北京:国防工业出版社, 2008:29-30. TAO C H, ZHONG P D. Failure analysis and prevention for rotor in aero-engine[M]. Beijing:National Defense Industry Press, 2008:29-30(in Chinese).
[23] 唐海军, 曹大树, 姚红宇. 某发动机空中停车事件的失效分析[J]. 航空学报, 2010, 31(2):285-289. TANG H J, CAO D S, YAO H Y. Failure analysis on in-flight shutdown of an aero engine[J]. Acta Aeronautica et Astronautica Sinica, 2010, 31(2):285-289(in Chinese).
[24] 曹爽, 岳建平, 马文. 基于特征选择的双边滤波点云去噪算法[J]. 东南大学学报(自然科学版), 2013, 11(43):351-354. CAO S, YUE J P, MA W. Bilateral filtering denoise algorithm for point cloud based on feature selection[J]. Journal of Southeast University(Natural Science Edition), 2013, 11(43):351-354(in Chinese).
[25] 徐工, 程效军. 基于小波技术的散乱点云自适应压缩算法[J]. 同济大学学报(自然科学版), 2013, 41(11):1738-1743. XU G, CHENG X J. Adaptive reduction of scattered point clouds based on wavelet technology[J]. Journal of Tongji University(Natural Science), 2013, 41(11):1738-1743(in Chinese).
[26] WANG T, DING H P, WANG H. Virtual remanufacturing:cross-section curve reconstruction for repairing a tip-defective blade[J]. Proceedings of the Institution of Mechanical Engineers, Part C:Journal of Mechanical Engineering Science, 2015, 229(17):3141-3152.
[27] BOEING Company. CFM56-7 Boeing aircraft maintenance manual, chapter 72 engine[S]. 2010.
[28] AIRBUS Company. CFM56-5 Airbus aircraft maintenance manual, chapter 72 engine[S]. 2011.
[29] Westinghouse. AN 02B-110BE-4 J34-WE-48 aircraft engine parts manual[S]. 1949.
[30] Westinghouse. AN 02B-110BA-3 J34-WE-22 aircraft engine overhaul instructions[S]. 1949.

E-mail：hkxb@buaa.edu.cn

关于我们

期刊社服务

专业学科

封面文章

友情链接

主管单位：中国科学技术协会主办单位：中国航空学会北京航空航天大学

航空发动机损伤叶片再制造修复方法与实现

Method and implementation of remanufacture and repair of aircraft engine damaged blades

PDF (PC)

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	刘佳奇, 冯蕴雯, 路成, 薛小锋, 潘维煌. 基于智能神经网络的航空发动机运行安全分析[J]. 航空学报, 2022, 43(9): 625375-625375.
[2]	张烁, 刘治汶. 航空发动机轴承故障结构化贝叶斯稀疏表示[J]. 航空学报, 2022, 43(9): 625056-625056.
[3]	牛广越, 段发阶, 周琦, 刘志博. 基于微波相位差测距的叶尖间隙动态测量方法[J]. 航空学报, 2022, 43(9): 625396-625396.
[4]	张忠强, 张新, 王家序, 刘治汶. 基于重加权谱峭度方法的航空发动机故障诊断[J]. 航空学报, 2022, 43(9): 625445-625445.
[5]	杨晓伟, 葛曜文, 邓文翔, 姚建勇, 周宁. 航空发动机导叶控制机构作动筒主动容错控制[J]. 航空学报, 2022, 43(9): 625464-625464.
[6]	韩淞宇, 邵海东, 姜洪开, 张笑阳. 基于提升卷积神经网络的航空发动机高速轴承智能故障诊断[J]. 航空学报, 2022, 43(9): 625479-625479.
[7]	杜建建, 潘贤德, 刘天一. 航空发动机角接触球轴承轴向力间接测量方法[J]. 航空学报, 2022, 43(9): 625457-625457.
[8]	曹明, 王鹏, 左洪福, 曾海军, 孙见忠, 杨卫东, 魏芳, 陈雪峰. 民用航空发动机故障诊断与健康管理现状、挑战与机遇Ⅱ: 地面综合诊断、寿命管理和智能维护维修决策[J]. 航空学报, 2022, 43(9): 625574-625574.
[9]	段发阶, 牛广越, 周琦, 傅骁, 蒋佳佳. 航空发动机叶尖间隙在线测量技术研究综述[J]. 航空学报, 2022, 43(9): 626014-626014.
[10]	郑覃, 杨小贺, 叶俊, 冯锦璋. 内涵工况对风扇增压级双涵匹配的影响[J]. 航空学报, 2022, 43(7): 125477-125477.
[11]	李定骏, 杨镠育, 孙帆, 江鹏, 陈艺文, 王铁军. 预热温度对热障涂层表面裂纹形成的影响[J]. 航空学报, 2022, 43(6): 526184-526184.
[12]	汪博, 高培鑫, 马辉, 孙伟, 林君哲, 李晖, 韩清凯, 刘中华. 航空发动机管路系统动力学特性综述[J]. 航空学报, 2022, 43(5): 25332-025332.
[13]	张佩宇, 周鑫, 李应红. 单晶涡轮叶片高能束修复研究进展[J]. 航空学报, 2022, 43(4): 525610-525610.
[14]	靳玉林, 刘治汶, 陈予恕. 航空发动机双转子系统叶片-机匣碰摩故障模拟[J]. 航空学报, 2022, 43(12): 425072-425072.
[15]	孙晓峰, 董旭, 张光宇, 王卓, 孙大坤. 特征值理论在稳定性预测中的应用研究进展[J]. 航空学报, 2022, 43(10): 527408-527408.