CN116579162A - Temperature field, defect analysis and stress field simulation method for directional cast crystal blade - Google Patents
Temperature field, defect analysis and stress field simulation method for directional cast crystal blade Download PDFInfo
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- CN116579162A CN116579162A CN202310553032.3A CN202310553032A CN116579162A CN 116579162 A CN116579162 A CN 116579162A CN 202310553032 A CN202310553032 A CN 202310553032A CN 116579162 A CN116579162 A CN 116579162A
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- 230000007547 defect Effects 0.000 title claims abstract description 31
- 238000004088 simulation Methods 0.000 title claims abstract description 28
- 238000000034 method Methods 0.000 title claims abstract description 22
- 238000004458 analytical method Methods 0.000 title claims abstract description 17
- 239000013078 crystal Substances 0.000 title claims abstract description 17
- 238000005266 casting Methods 0.000 claims abstract description 41
- 238000009826 distribution Methods 0.000 claims abstract description 32
- 238000001816 cooling Methods 0.000 claims abstract description 24
- 238000007689 inspection Methods 0.000 claims abstract description 21
- 238000010586 diagram Methods 0.000 claims abstract description 20
- 239000000956 alloy Substances 0.000 claims description 12
- 229910045601 alloy Inorganic materials 0.000 claims description 11
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 239000010949 copper Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 238000007711 solidification Methods 0.000 claims description 5
- 230000008023 solidification Effects 0.000 claims description 5
- 238000004364 calculation method Methods 0.000 claims description 4
- 230000000694 effects Effects 0.000 claims description 4
- 230000005484 gravity Effects 0.000 claims description 3
- 238000013507 mapping Methods 0.000 claims description 3
- 239000007790 solid phase Substances 0.000 claims description 3
- 238000012546 transfer Methods 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 abstract description 6
- 238000002474 experimental method Methods 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000009416 shuttering Methods 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
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- Pure & Applied Mathematics (AREA)
- Investigating Or Analyzing Materials Using Thermal Means (AREA)
Abstract
The invention discloses a method for simulating a temperature field, a defect analysis and a stress field of a directional cast crystal blade, which comprises the following steps: constructing a blade model, and then guiding the blade model into casting simulation software and performing inspection processing and grid division; then, parameter setting is carried out in casting simulation software, and then simulation is carried out; and obtaining a temperature field distribution diagram, a shrinkage cavity defect diagram and a stress strain distribution diagram of the blade through simulation, and analyzing the results. The invention adopts the full-flow simulation technology to simulate the temperature field and the cooling rate of the blade, can check the temperature change of the blade in the casting process, simulate the shrinkage cavity shrinkage porosity of the blade, can obtain the quality condition of the blade under the process, can check the stress change state of the blade at uneven thickness by simulating the stress distribution of the blade under the service state, extract the grid information of the blade, realize the transmissibility of the grid, and provide references for improving the casting process and the structural parameters of the blade.
Description
Technical Field
The invention belongs to the technical field of simulation, and particularly relates to a method for analyzing temperature fields and defects of a directional cast crystal blade and simulating stress fields.
Background
The turbine blade is used as a component with the highest temperature, the most complex stress and the worst application environment of the gas turbine, plays a vital role in the safe operation and the efficiency improvement of a unit, and the tissue compactness and the performance superiority of the blade are very dependent on alloy materials and a preparation process. The structure of the turbine blade is improved into a directional columnar crystal by a directional solidification technology, so that the high-temperature performance of the turbine blade can be greatly improved. However, most of the existing turbine blade materials of the gas turbine still use directional casting crystals, and due to the limitations of alloy smelting technology and solidification technology, the blades can generate defects such as shrinkage cavity shrinkage porosity and the like, and the defects can only be detected by an experimental method, and some parts can not be detected, so that the evaluation of the blades can be influenced, and the service state of the blades can be further influenced.
Disclosure of Invention
In order to solve the technical problems in the prior art, the invention aims to provide a method for analyzing the temperature field and the defects of a directional cast crystal blade and simulating the stress field.
In order to achieve the above purpose and achieve the above technical effects, the invention adopts the following technical scheme:
a method for simulating a temperature field, a defect analysis and a stress field of a directional cast crystal blade comprises the following steps:
constructing a blade model, a water-cooling copper plate model, a pouring system model and a furnace body model, and introducing the model into casting simulation software to perform inspection and grid division; then, setting parameters of the simulation orientation in casting simulation software, and then performing simulation; and obtaining a temperature field distribution diagram, a shrinkage cavity defect diagram and a stress strain distribution diagram of the blade through simulation, and respectively carrying out result analysis.
Further, when a blade model, a water-cooling copper plate model, a pouring system model and a furnace body model are constructed, UG or SolidWorks are respectively adopted for modeling, and after modeling is completed, the models are exported in an igs or iges format.
Further, the step of importing the simulation data into the casting simulation software for inspection and grid division comprises the following steps:
firstly, performing geometric inspection, then assembling the built blade model, the water-cooled copper plate model, the casting system model and the furnace body model, performing geometric inspection after the assembly is finished, performing two-dimensional grid division after the inspection, and drawing smaller two-dimensional grids of the blade; then, grid inspection, such as grid defect, is carried out, and a grid repairing tool is used for repairing; after the two-dimensional grid is drawn, the hearth with the drawn grid is exported in a mesh format; then dividing three-dimensional grids, wherein the grid size is different due to the thickness of the part, adding a mould shell to the casting, and dividing two-dimensional grids and three-dimensional grids to the mould shell.
Furthermore, the casting simulation software is ProCAST; the furnace chamber export format of the drawn grid is a mesh format.
Further, the geometric inspection includes inspection of missing faces, overlapping faces, and intersecting faces.
Further, the parameter setting of the simulation orientation in the casting simulation software comprises: setting the gravity direction; setting the material type, casting temperature and filling percentage of the alloy and the mould shell; the heat transfer coefficient, the casting temperature, the drawing rate and the flow rate of the solution.
Further, the step of obtaining the cooling rate profile of the blade includes:
the temperature field of the blade is obtained through simulation and based on the temperature field, the temperature field is determined through Mapping Factor criterion according to the formula = aR b G c L d And calculating, wherein a, b, c, d is a constant, R is a solidification rate, G is a temperature gradient, L is a cooling rate, determining the values according to the characteristics of the alloy, inputting liquidus and solidus temperature values of the alloy, and obtaining a cooling rate distribution diagram of the blade through calculation for observing the temperature change and the cooling effect of the blade during casting.
Further, the step of obtaining the shrinkage porosity distribution map of the blade comprises the following steps:
in order to check the casting quality of the blade, whether the blade has shrinkage porosity defects or not is checked, according to the temperature field distribution and the solid phase fraction distribution of the blade obtained through simulation, a Niyama criterion is used, in ProCAST software, POROS is set to be more than 0, a shrinkage porosity distribution map of the blade is obtained through simulation, wherein when the volume fraction is less than 0.01, the shrinkage porosity is microscopic, and when the volume fraction is higher than 0.01, the shrinkage porosity is macroscopic, and the internal shrinkage porosity can be checked through a slicing mode.
Further, the step of obtaining the stress-strain distribution map of the blade includes:
extracting grid information in the blade, introducing a blade model into Ansys or Abaqus for grid division by referring to the grid information, wherein the size of the drawn grid is the same as that of the grid in casting simulation software, transmitting the grid information, and obtaining a stress-strain distribution diagram of the blade under the working condition service by setting simulation parameters in the Ansys.
Compared with the prior art, the invention has the beneficial effects that:
the invention discloses a method for simulating a temperature field, a defect analysis and a stress field of a directional cast crystal blade, which adopts a full-flow simulation technology to simulate the temperature field and the cooling rate of the blade, can check the temperature change of the blade in the casting process, simulate shrinkage cavity shrinkage porosity of the blade, can obtain the quality condition of the blade under the process, can check the stress change state of the uneven thickness part of the blade by simulating the stress distribution of the blade under the service state, extract the grid information of the blade, realize the transmissibility of the grid, more conveniently obtain the relation among the temperature field evolution, the cooling rate, the shrinkage cavity shrinkage porosity defect and the stress distribution of any position of the blade, and realize the flow simulation of the temperature field-the cooling rate-the shrinkage cavity shrinkage porosity defect-the stress field of the blade by connecting the fields in series.
Drawings
FIG. 1 is a schematic view of a blade model according to the present invention;
FIG. 2 is a grid of blades of the present invention;
FIG. 3 is a temperature field distribution diagram of a blade of the present invention;
FIG. 4 is a graph of the cooling rate profile of a blade of the present invention;
FIG. 5 is a graph of shrinkage porosity and shrinkage cavity defects of a blade according to the present invention;
FIG. 6 is a stress-strain distribution diagram of a blade according to the present invention.
Detailed Description
The present invention is described in detail below so that advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making clear and unambiguous the scope of the present invention.
The following presents a simplified summary of one or more aspects in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later.
As shown in fig. 1-6, a method for simulating a temperature field, a defect analysis and a stress field of a directional cast crystal blade comprises the following steps:
1) Firstly, modeling software such as UG, solidWorks is used for building a blade model, a cooling channel is arranged in the blade, the temperature of the blade is reduced through air flow, and as shown in figure 1, the file output format is an igs format or an iges format; the same method is adopted to build a water-cooling copper plate model, a pouring system model and a furnace body model, and the output is in an igs format or an iges format.
2) The model is imported into casting simulation software such as ProCAST and the like for checking and grid division, and the specific steps are as follows:
firstly, performing geometric inspection including surface missing, surface overlapping, surface crossing and the like, then assembling the built blade model, the water-cooling copper plate model, the pouring system model and the furnace body model, performing geometric inspection after the assembly is finished, performing two-dimensional grid division after the inspection, and drawing smaller two-dimensional grids of the blade; then, grid inspection, such as grid defect, is carried out, and a grid repairing tool is used for repairing; after the two-dimensional grid is drawn, the hearth with the drawn grid is exported in a mesh format; then, three-dimensional grids are divided, the grid size is different according to the thickness of the part, the die shell is added to the casting, and the two-dimensional grids and the three-dimensional grids are divided for the die shell, as shown in fig. 2.
3) Parameter setting of simulation orientation is carried out in casting simulation software, and the method comprises the following steps: setting the gravity direction; setting the material type, casting temperature and filling percentage of the alloy and the mould shell; and setting parameters such as heat transfer coefficient, casting temperature, drawing rate, flow rate of solution and the like. It should be noted that, in order to obtain accurate results, besides using the self-contained material library of the casting simulation software, the characteristics and thermophysical parameters of the alloy and the shuttering material can be calculated by JMatPro, thermo-Calc, pandat and other software, and thermophysical parameters of the material can also be obtained through a large number of experiments, and finally, a series of operation parameters are set to perform simulation, wherein the operation parameters include operation time, initial time step, maximum time step, convergence degree and the like.
4) The temperature field of the blade is obtained by simulation, as shown in fig. 3, and based thereon, by Mapping Factor criterion, the formula=ar b G c L d The calculation is carried out, wherein a, b, c, d is constant, R is solidification rate, G is temperature gradient, L is cooling rate, the values are determined according to the characteristics of the alloy, liquidus and solidus temperature values of the alloy are input, and a cooling rate distribution diagram of the blade is obtained through calculation, as shown in fig. 4, the change of temperature and the cooling effect of the blade during pouring are mainly observed, and references are provided for adjustment of casting process parameters of the blade and design of uneven thickness parts of the blade.
5) In order to check the casting quality of the blade and observe whether the blade has shrinkage cavity defects or not, the invention uses Niyama criterion according to the simulated temperature field and solid phase fraction distribution of the blade, and in ProCAST software, POROS is set to be more than 0, and the shrinkage cavity distribution map of the blade is simulated, wherein when the volume fraction is less than 0.01, the shrinkage cavity is microscopic, when the volume fraction is higher than 0.01, the shrinkage cavity is macroscopic, and the internal shrinkage cavity can be observed by using a slicing mode, as shown in figure 5.
6) Since the two-dimensional and three-dimensional grids of the blade are drawn in the casting simulation software, the grids at different positions of the blade represent information of each position, such as temperature and cooling rate values, in order to reduce errors, the grid information in the blade is extracted, a blade model is imported into Ansys, abaqus and other software to divide the grids by referring to the grid information, the size of the drawn grids is the same as that of the grids in the casting simulation software, the transmission of the grid information is performed, and the stress strain distribution of the blade under the service condition is obtained by setting simulation parameters (mainly including stress state, temperature and the like) in Ansys, as shown in fig. 6.
7) The casting process parameters of the blade can be improved by analyzing the temperature field distribution diagram, the cooling rate distribution diagram, the shrinkage cavity shrinkage porosity defect diagram and the stress strain distribution diagram of the blade, so that the structure of the blade is further improved.
Parts or structures of the present invention, which are not specifically described, may be existing technologies or existing products, and are not described herein.
The foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes or direct or indirect application in other related arts are included in the scope of the present invention.
Claims (9)
1. The method for simulating the temperature field, the defect analysis and the stress field of the directional cast crystal blade is characterized by comprising the following steps of:
constructing a blade model, a water-cooling copper plate model, a pouring system model and a furnace body model, and introducing the model into casting simulation software to perform inspection and grid division; then, setting parameters of the simulation orientation in casting simulation software, and then performing simulation; and obtaining a temperature field distribution diagram, a shrinkage cavity defect diagram and a stress strain distribution diagram of the blade through simulation, and respectively carrying out result analysis.
2. The method for simulating the temperature field, the defect analysis and the stress field of the directional cast crystal blade according to claim 1, wherein when a blade model, a water-cooled copper plate model, a pouring system model and a furnace body model are constructed, UG or Solidworks are adopted for modeling respectively, and after modeling is completed, the model is derived in an igs or iges format.
3. The method for simulating the temperature field, the defect analysis and the stress field of the directional cast crystal blade according to claim 1, wherein the step of introducing the directional cast crystal blade into casting simulation software for inspection and meshing comprises the following steps:
firstly, performing geometric inspection, then assembling the built blade model, the water-cooled copper plate model, the casting system model and the furnace body model, performing geometric inspection after the assembly is finished, performing two-dimensional grid division after the inspection, and drawing smaller two-dimensional grids of the blade; then, grid inspection, such as grid defect, is carried out, and a grid repairing tool is used for repairing; after the two-dimensional grid is drawn, the hearth with the drawn grid is exported in a mesh format; then dividing three-dimensional grids, wherein the grid size is different due to the thickness of the part, adding a mould shell to the casting, and dividing two-dimensional grids and three-dimensional grids to the mould shell.
4. A method for simulating a temperature field, a defect analysis and a stress field of a directional cast crystal blade according to claim 3, wherein the casting simulation software is ProCAST; the furnace chamber export format of the drawn grid is a mesh format.
5. A method of simulating the temperature field, defect analysis and stress field of a directionally cast wafer blade as recited in claim 3, wherein said geometric inspection includes inspection of missing facets, overlapping facets and intersecting facets.
6. A method of simulating the temperature field, defect analysis and stress field of a directionally cast wafer blade as claimed in claim 1, wherein the setting of parameters for simulating the orientation in the casting simulation software comprises: setting the gravity direction; setting the material type, casting temperature and filling percentage of the alloy and the mould shell; the heat transfer coefficient, the casting temperature, the drawing rate and the flow rate of the solution.
7. The method for simulating the temperature field, defect analysis and stress field of a directionally cast wafer blade as recited in claim 1, wherein the step of obtaining the cooling rate profile of the blade comprises:
the temperature field of the blade is obtained through simulation and based on the temperature field, the temperature field is determined through Mapping Factor criterion according to the formula = aR b G c L d And calculating, wherein a, b, c, d is a constant, R is a solidification rate, G is a temperature gradient, L is a cooling rate, determining the values according to the characteristics of the alloy, inputting liquidus and solidus temperature values of the alloy, and obtaining a cooling rate distribution diagram of the blade through calculation for observing the temperature change and the cooling effect of the blade during casting.
8. The method for simulating the temperature field, the defect analysis and the stress field of the directional cast crystal blade according to claim 1, wherein the step of obtaining the shrinkage cavity distribution map of the blade comprises the following steps:
in order to check the casting quality of the blade, whether the blade has shrinkage porosity defects or not is checked, according to the temperature field distribution and the solid phase fraction distribution of the blade obtained through simulation, a Niyama criterion is used, in ProCAST software, POROS is set to be more than 0, a shrinkage porosity distribution map of the blade is obtained through simulation, wherein when the volume fraction is less than 0.01, the shrinkage porosity is microscopic, and when the volume fraction is higher than 0.01, the shrinkage porosity is macroscopic, and the internal shrinkage porosity can be checked through a slicing mode.
9. The method for simulating the temperature field, the defect analysis and the stress field of the oriented cast crystal blade according to claim 1, wherein the step of obtaining the stress-strain distribution map of the blade comprises the following steps:
extracting grid information in the blade, introducing a blade model into Ansys or Abaqus for grid division by referring to the grid information, wherein the size of the drawn grid is the same as that of the grid in casting simulation software, transmitting the grid information, and obtaining a stress-strain distribution diagram of the blade under the working condition service by setting simulation parameters in the Ansys.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310553032.3A CN116579162A (en) | 2023-05-17 | 2023-05-17 | Temperature field, defect analysis and stress field simulation method for directional cast crystal blade |
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| CN202310553032.3A CN116579162A (en) | 2023-05-17 | 2023-05-17 | Temperature field, defect analysis and stress field simulation method for directional cast crystal blade |
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| CN202310553032.3A Pending CN116579162A (en) | 2023-05-17 | 2023-05-17 | Temperature field, defect analysis and stress field simulation method for directional cast crystal blade |
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- 2023-05-17 CN CN202310553032.3A patent/CN116579162A/en active Pending
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