Reliability evaluation of turbine blades considering contact variability on working surface of shrouds
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摘要:
针对涡轴/涡桨发动机动力涡轮叶片带冠结构的振动问题，建立了考虑叶冠工作面接触特性分散性对连接界面接触刚度影响的叶片振动分析模型。模型考虑了加工公差、工作载荷环境变化和界面磨损损伤对叶冠工作面接触状态和叶片共振转速线分布特性的综合影响，同时评估了该结构系统发生疲劳断裂失效的概率。结果表明：由于加工公差和界面磨损损伤的共同影响，叶冠工作面接触刚度显著下降，进而降低了叶片周向一弯振型的振动频率。这使得该阶振型的叶片共振转速偏离设计值并与工作转速区相交，造成叶片有一定概率发生共振、进而发生高周疲劳失效，从而降低结构系统可靠性。
Abstract:In view of the shrouded structure system of power turbine blades of the turboshaft/turboprop engine and its reliability to processing errors, changes in working load environment and wear and damage to the contact surfaces between shrouds were analyzed. A blade vibration analysis model considering variability of contact surface of the shroud working surface on the contact stiffness of the interface was established, and the probability of fatigue fracture failure of the structural system was evaluated. Simulation results indicated that joint effect of processing errors and interface wear and damage can cause a decrease in the vibration frequency of the blade. This causes the resonant rotational speed of the blade in this vibration mode to deviate from the design value and intersect with the operating speed range, resulting in the risk of resonance and high-cycle fatigue failure, thus reducing the reliability of the structural system.
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Key words:
- turbine blades /
- structure system /
- damage and failure /
- dynamic characteristic /
- reliability
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图 2 结构系统失效表征参数及其影响因素
Figure 2. Structural system failure characteristic parameters and influencing factors
图 3 单失效模式下结构系统失效概率
Figure 3. Failure probability of structural system under single failure mode
图 6 考虑界面接触特性下带冠叶片可靠性的研究思路
Figure 6. Research approach for the reliability of blades with shrouds considering interface contact characteristics
图 7 特征参数非确定影响下第1级叶片Campbell图
Figure 7. Campbell diagram of first turbine blade under uncertainty of feature parameters
图 8 特征参数非确定影响下第2级叶片Campbell图
Figure 8. Campbell diagram of second turbine blade under uncertainty of feature parameters
表 1 有限元模型材料参数（室温为20 ℃）
Table 1. Material parameters of finite element model（room temperature of 20 ℃）
参数 动力涡轮叶片 第1级 第2级 $ \rho $/（kg/m3） 8100 8100 E/GPa 208 208 H/MPa 1190 1190 v 0.33 0.33 
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表 2 动力涡轮叶片叶冠工作面间过盈量设定值
Table 2. Interference fit setting for working surface of turbine blade
mm 叶片位置 设计值 加工公差影响 界面磨损损伤影响 综合影响 第1级 +0.05 −0.066～0 −0.300～0 −0.366～+0.05 第2级 +0.20 −0.066～0 −0.150～0 −0.216～+0.20
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表 3 两级动力涡轮叶冠接触刚度计算值（设计状态）
Table 3. Contact stiffness calculation value of two-stage turbine blade shroud （design state）
叶片位置 接触状态图 接触压力图 接触刚度图 接触刚度/105 （N/m） Kn Kt 第1级 
7.06 5.67 第2级 
8.43 6.76
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表 4 加工公差和界面磨损损伤对界面接触刚度影响
Table 4. Influence of processing errors and interface wear on contact stiffness of interface
叶片位置 接触刚度
量符号接触刚度
（设计状态）/
105 （N/m）仅考虑加工公差影响 仅考虑界面磨损损伤影响 接触刚度/105 （N/m） 相对差/% 接触刚度/105 （ N/m） 相对差/% 第1级 Kn 7.06 5.15 −27.05 3.99 −43.48 Kt 5.67 4.13 −27.16 3.20 −43.56 第2级 Kn 8.43 6.54 −22.42 5.10 −39.50 Kt 6.76 5.25 −22.34 4.09 −39.50
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表 5 工作状态下两级动力涡轮叶片下前5阶振型与频率（自由边界）
Table 5. Top five vibrational frequencies and mode of two-stage turbine blades at operating （free boundary）
叶片位置 参数 周向一弯 轴向一弯 尾缘一弯 展向扭转 复合振型 第1级 振型图 
固有频率/Hz 937.8 2138.1 5864.8 8843.6 11007 第2级 振型图 
固有频率/Hz 387.55 1272.4 3776.8 7894.9 9922.5
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表 6 考虑叶冠约束作用对动力涡轮叶片前5阶振动频率的影响（设计状态）
Table 6. Effect of shroud constraint on the top five vibration frequencies of turbine blade （design state）
振型 第1级动力涡轮叶片 第2级动力涡轮叶片 振动频率/Hz 相对差/% 振动频率/Hz 相对差/% 不考虑叶冠接触状态 考虑叶冠接触状态 不考虑叶冠接触状态 考虑叶冠接触状态 周向一弯 937.8 1868.2 99.21 387.55 1294.9 234 轴向一弯 2138.1 3142.4 46.97 1272.4 2512.3 97.4 尾缘一弯 5864.8 6440.5 9.82 3776.8 4410.2 16.77 展向扭转 8843.6 9510.8 7.54 7894.9 8509.2 7.78 复合振型 11007 11249 2.20 9922.5 10303 3.83
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表 7 不同状态下动力涡轮叶片前3阶振动频率
Table 7. Top three vibration frequencies of turbine blade under different states
振型 第1级动力涡轮叶片 第2级动力涡轮叶片 振动频率/ Hz 相对差/% 振动频率/ Hz 相对差/% 装配状态 设计状态 装配状态 设计状态 周向一弯 1703.3 1868.2 9.68 1286.6 1294.9 0.65 轴向一弯 3076.5 3142.4 2.14 2403 2512.3 4.55 尾缘一弯 4639.2 6440.8 38.83 3126.1 4410.2 41.07
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