航空学报 > 2024, Vol. 45 Issue (13): 630037-630037   doi: 10.7527/S1000-6893.2024.30037

航空发动机高性能制造专栏

基于先进激光加工技术的下一代航空发动机跨尺度整体式承力薄壁构件设计方法与应用

张少平1(), 郭会明1, 高彤2, 张卫红2   

  1. 1.中国航发四川燃气涡轮研究院,成都 610500
    2.西北工业大学 机电学院,西安 710072
  • 收稿日期:2023-12-28 修回日期:2024-01-22 接受日期:2024-03-06 出版日期:2024-07-15 发布日期:2024-04-10
  • 通讯作者: 张少平 E-mail:zhangshaoping@aecc.cn
  • 基金资助:
    国防科研基础项目(JCKY2022205B020);国家自然科学基金重点项目(12032018)

Design and manufacturing method of multi-scale integrated load bearing thin-walled structure for application in next-generation aeroengine based on advanced laser processing technology

Shaoping ZHANG1(), Huiming GUO1, Tong GAO2, Weihong ZHANG2   

  1. 1.AECC Sichuan Gas Turbine Establishment,Chengdu 610500,China
    2.School of Mechanical Engineering,Northwestern Polytechnical University,Xi’an 710072,China
  • Received:2023-12-28 Revised:2024-01-22 Accepted:2024-03-06 Online:2024-07-15 Published:2024-04-10
  • Contact: Shaoping ZHANG E-mail:zhangshaoping@aecc.cn
  • Supported by:
    Defense Industrial Technology Development Program(JCKY2022205B020);National Natural Science Foundation of China(12032018)

摘要:

由宏观骨架-细观点阵-微观表面构成的多尺度整体式结构是一类极具高性能、多功能、轻量化潜力的新型结构形式,日渐成熟的先进激光加工技术不仅极大提升了高性能结构的制造能力,也为新型复杂结构的制造提供了可能。在简要总结宏观骨架、细观点阵、微观表面设计与制造现状基础上,提出了以先进激光加工技术为制造手段的多尺度整体式结构设计方法。以中介机匣为例,采用拓扑优化技术设计了主承力骨架结构,通过在拓扑优化低密度区域或低应力区域填充可制造点阵的方式完成了轻量化点阵设计,与实壁铸造件相比减重20%以上;在流道表面设计了导流减阻微沟槽结构,采用超快激光表面刻蚀加工,仿真模拟表明微沟槽减阻效果超过10%。采用先进激光加工技术开展了多尺度整体式结构设计的应用探索,为下一代航空发动机结构研制提供了可供借鉴的新途径。

关键词: 多尺度结构, 拓扑优化, 点阵结构, 增材制造, 中介机匣, 激光加工

Abstract:

The multi-scale structure, composed of the macro skeleton, lattice and micro surface, represents a novel type of structure with potential for high performance, multifunctionality and lightweight design. Advanced laser processing technology not only enhances the manufacturing capacity of high-performance structures, but also provides possibilities for the manufacturing of new complex structures. After providing a brief overview of the current design and manufacturing techniques on macro skeleton, lattice and micro surface, this paper introduces a multi-scale structure design method for advanced laser processing technology. Taking the intermediate case of a turbine engine as an example, the main load-bearing skeleton is designed using topology optimization technology for additive manufacturing. The lightweight lattice design is carried out by filling manufacturable lattice in low-density areas in topology oiptimization or low-stress areas in the optimized model, resulting in a weight reduction of over 20% compared to the original design. Additionally, micro groove structures for drag reduction are designed on the surface of the airflow channel for ultrafast laser etching processing. Simulation results indicate that the micro grooves exhibit a drag reduction effect exceeding 10%. By exploring the multi-scale integrated structure design based on advanced laser processing technology, this study establishes a creative structural design procedure and offers a valuable approach for the development of next-generation aeroengine structures.

Key words: multi-scale structure, topology optimization, lattice structure, additive manufacturing, intermediate case, laser processing

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