复合材料涡轮轴结构损伤演化及失效机理

沙云东; 黄靖轩; 骆丽; 白旭

doi:10.13224/j.cnki.jasp.20210572

复合材料涡轮轴结构损伤演化及失效机理

doi: 10.13224/j.cnki.jasp.20210572

沈阳航空航天大学航空发动机学院辽宁省航空推进系统先进测试技术重点实验室，沈阳 110136

基金项目: 中国航空发动机集团产学研合作项目（HFZL2018CXY019）

详细信息

作者简介:
沙云东（1966-），男，教授，博士，主要从事航空发动机强度、振动及噪声方面的研究

中图分类号: V232.2
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- 文章访问数: 43
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- 被引次数: 0
出版历程
- 收稿日期: 2021-10-11
- 网络出版日期: 2024-01-06

Damage evolution and failure mechanism of composite turbine shaft structure

Liaoning Key Laboratory of Advanced Measurement and Test Technology for Aviation Propulsion System，School of Aero-engine，Shenyang Aerospace University，Shenyang 110136，China

摘要

摘要:
针对连续纤维增强复合材料涡轮轴结构损伤演化及失效机理分析，基于宏-细观力学跨尺度分析方法，建立了与轴结构试验件尺寸相符合的有限元仿真计算模型及细观力学代表体积元（RVE）模型，预测轴结构的损伤演化并分析其失效机理。反向扭矩下，[45]₆轴结构的损伤始于界面开裂，裂纹向两侧钛合金扩展，钛合金的剪切变形最终带动纤维的断裂；正向扭矩下，[45]₁₀轴结构的损伤始于基体损伤，断口两侧钛合金相互挤压摩擦，最终将纤维剪断。开展复合材料失效模式验证试验，通过声发射及扫描电镜技术，实现对失效过程中不同失效模式的判别。将仿真结果与试验结果进行对比验证，验证了模型和方法的有效性。模拟涡轮轴结构在扭转载荷下的损伤演化过程及失效机理，预测失效强度。结果表明：0°和90°铺层时扭转强度最低，45°铺层时扭转强度最高，提高近3倍。本文研究提出的预测模型及分析结论为纤维增强复合材料的设计和应用提供依据。
- 复合材料涡轮轴 /
- 损伤演化 /
- 失效机理 /
- 失效强度 /
- 铺层角度
Abstract:
For continuous fiber reinforced composites turbo-shaft structural damage evolution and failure mechanism analysis, based on the macro-mechanics and meso-mechanics analysis method of cross-scale, a finite element simulation model with the same size of the shaft structure verification model and a micro-mechanics representative volume element (RVE) model was established. The damage evolution of shaft structure was predicted and its failure mechanism was analyzed. Under reverse torque, the damage of [45]₆ shaft structure structure began with interface cracking, the cracks were extended to both sides of titanium alloy, and the shear deformation of titanium alloy finally drove the fiber fracture. Under forward torque, the damage of [45]₁₀ shaft structure began with matrix damage, titanium alloys on both sides of the fracture were pressed against each other, and finally the fiber was cut. The failure mode verification experiment of composite shaft structure was carried out, different failure modes in the failure process were identified by acoustic emission and scanning electron microscopy techniques. The simulation results were compared with experiment results to verify the validity of the model and method. The damage evolution process and failure mechanism of the turbo-shaft structure under torsional load were simulated and the failure strength was predicted. The damage evolution process and failure mechanism of turbo-shaft structure under torsional load were simulated and the failure strength was predicted. The results showed that the torsional strength was the lowest when the layer was laid at 0° and 90°, and the highest when the layer was laid at 45°, which increased nearly three times. The prediction model and analysis conclusions could provide a basis for the design and application of fiber reinforced composites.
- composite turbine shaft /
- damage evolution /
- failure mechanism /
- failure strength /
- layer angle

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图 1 纤维增强复合材料轴结构研究尺度

Figure 1. Fiber reinforced composite shaft structure research scale

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图 2 四边形排列的RVE模型的二维几何表示

Figure 2. Two dimensional periodic structure of RVE model of square array

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图 3 界面单元本构关系

Figure 3. Constitutive relation of interface layer

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图 4 试验系统平面图

Figure 4. Experiment site plan

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图 5 安装状态

Figure 5. Installation diagram

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图 6 试验件尺寸（单位：mm）

Figure 6. Dimensions of shafts (unit: mm)

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图 7 轴结构模型建立

Figure 7. Dangerous position

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图 8 RVE模型网格划分

Figure 8. Mesh generation of RVE model

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图 9 [45]₆复合材料轴界面损伤模型演化

Figure 9. Evolution of [45]₆ composite turbine shaft interface damage model

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图 10 [45]₆复合材料轴基体损伤模型演化

Figure 10. Evolution of [45]₆ composite turbine shaft matrix damage model

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图 11 [45]₆复合材料轴纤维损伤模型演化

Figure 11. Evolution of [45]₆ composite turbine shaft fiber damage model

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图 12 [45]₁₀复合材料轴基体损伤模型演化

Figure 12. Evolution of [45]₁₀ composite turbine shaft matrix damage model

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图 13 [45]₁₀复合材料轴纤维损伤模型演化

Figure 13. Evolution of [45]₁₀ composite turbine shaft fiber damage model

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图 14 低压涡轮轴结构有限元模型

Figure 14. Finite element model of low pressure turbine shaft structure

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图 15 低压涡轮轴结构网格划分

Figure 15. Mesh generation of low pressure turbine shaft structure

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图 16 低压涡轮轴扭转角-转矩图

Figure 16. Torsional angle-torque of low pressure turbine shaft

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图 17 低压涡轮轴基体损伤模型演化

Figure 17. Evolution of low pressure turbine shaft matrix damage model

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图 18 低压涡轮轴纤维损伤模型演化

Figure 18. Evolution of low pressure turbine shaft fiber damage model

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图 19 低压涡轮轴分层损伤模型演化

Figure 19. Evolution of low pressure turbine shaft stratified damage model

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图 20 不同铺层角度下低压涡轮轴扭转角-扭矩

Figure 20. Torsional angle-torque of low pressure turbine shaft at different layer degrees

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图 21 不同铺层角度的扭转强度

Figure 21. Torsional strength at different fiber orientation

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表 1 轴结构断裂试验结果

Table 1. Fracture experiment results of shaft structure

轴结构	扭矩方向	试验值/（N·m）	断口状态
[45]₆	反向扭矩	−11812	45°和90°方向出现裂纹
[45]₁₀	正向扭矩	10418	90°方向出现裂纹

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表 2 轴结构失效模式试验结果

Table 2. Failure mode experiment results of shaft structure

轴结构	声发射信号监测	断口切割方案	断口形貌宏观观测	电镜扫描细观观测
[45]₆
[45]₁₀

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表 3 材料参数

Table 3. Material parameters

参数		材料
参数		SiC/TC4	TC4
E/GPa	E₁	234	122.5
	E₂	187
	E₃	187
ν	ν₁₂	0.23	0.3
	ν₂₃	0.27
	ν₁₃	0.23
G/GPa	G₁₂	64.38
	G₂₃	71.69
	G₁₃	64.38

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表 4 承载能力计算结果与试验结果

Table 4. Calculation results and experiment results of bearing capacity

轴结构	仿真值/（N·m）	试验值/（N·m）	误差/%	载荷描述
[45]₆	−10282.00	−11812.00	12.9	反向扭转
[45]₁₀	9601.85	10418.00	7.8	正向扭转

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表 5 低压涡轮轴基体失效分析

Table 5. Matrix failure analysis of low pressure turbine shaft

扭转角/（°）	扭矩/（N·m）	失效模式
2.41	2707.75	层3轴颈处失效
3.05	3330.89	层5轴颈处失效
3.21	3475.78	层1轴颈处失效
5.45	5513.93	层3失效开始向Ⅱ扩展
6.58	6566.40	层3失效已扩展至Ⅱ段，层1、层5失效已扩展至Ⅰ段
7.06	2156.44	层2、层4失效由轴颈处向 Ⅱ段扩展
7.38	361.268	层1、层5失效扩展至Ⅱ段前端

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表 6 低压涡轮轴纤维失效分析

Table 6. Fiber failure analysis of low pressure turbine shaft

扭转角/（°）	扭矩/（N·m）	失效模式
2.73	3047.13	层3轴颈处失效，并向Ⅰ段扩展
5.61	5674.12	层3失效已扩展至Ⅰ段，并向Ⅱ段扩展
6.58	6566.40	层4轴颈处失效，并同时沿Ⅰ、Ⅱ段扩展
6.74	6455.94	层2轴颈处失效，并同时沿Ⅰ、Ⅱ段扩展
7.06	2156.44	层1、层5轴颈处失效，并同时沿Ⅰ、Ⅱ段扩展
7.38	361.268	各层出现不同程度的失效

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表 7 低压涡轮轴分层失效分析

Table 7. Stratified failure analysis of low pressure turbine shaft

扭转角/（°）	扭矩/（N·m）	失效模式
6.90	5022.39	层2、层3轴颈处失效
7.06	2156.44	各层出现不同程度失效
7.38	361.268	各层失效向Ⅰ、Ⅱ段扩展

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