Effects of film hole diameter variations on overall cooling performance of a rotating turbine blade
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摘要:
选取涡轮旋转叶片为研究对象，针对加工制造过程中激光打孔以及涂层喷涂导致的气膜孔孔径与设计值不同的问题，对比分析了气膜孔孔径变化对叶片不同区域冷却效率的影响。根据对某型发动机相关数据的统计分析，激光加工后气膜孔孔径大于设计值，而在喷涂涂层后，孔径减小至设计值以下。据此，本文建立不同工况并进行耦合换热计算，结果表明：气膜孔孔径变化对外换热较强区域冷却效率的影响更为显著；近尾缘区域处综合冷却效率在气膜孔孔径达到设计值时最佳，其余位置上综合冷却效率与气膜孔孔径呈正相关，气膜孔径增加显著提升综合冷却效率，影响程度达164.13%/mm，远超孔径减小时的78.72%/mm；气膜孔孔径变化对前缘区域冷却效率影响程度较大，平均影响程度最高可达254.62%/mm，在设计时需要重点关注。
Abstract:In view of the problem that the film hole diameters are different from their design values caused by laser drilling and coating spraying during the manufacturing, the effects of film hole diameter change on the cooling effectiveness in different regions of the blade were analyzed for a rotating turbine blade. According to the statistics from a real engine, the diameter of the film hole was larger after laser processing but smaller after coating spraying relative to the design value. Based on this, different models were established and conjugate heat transfer simulations were carried out. The results showed that the change of film hole diameter had a more significant effect on the cooling effectiveness in the region with strong external heat transfer boundaries. The comprehensive cooling efficiency near the trailing edge region was the best when the film hole diameter reached the design value, and the efficiency was positively correlated with the film hole diameter in the other positions. The increase of the film hole diameter significantly improved the comprehensive cooling efficiency by 164.13%/mm, which was far more than 78.72%/mm when the film hole diameter decreased. The change of film hole diameter had a great influence on the cooling efficiency of the leading edge, and the average influence degree can be up to 254.62%/mm, which need to be paid more attention in the design.
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图 7 不同温度下DD6物性参数分布
Figure 7. Distribution of physical parameters of DD6 at different temperatures
图 8 不同温度下理想气体物性参数分布
Figure 8. Distribution of physical parameters of ideal gas at different temperatures
图 9 叶片前缘综合冷效分布
Figure 9. Overall cooling effectiveness distribution of blade leading edge
图 10 不同工况下监测点处综合冷效（叶片前缘）
Figure 10. Overall cooling effectiveness at monitoring points in different working conditions （blade leading edge）
图 11 叶片压力面综合冷效分布
Figure 11. Overall cooling effectiveness distribution of blade pressure side
图 12 不同工况下监测点处综合冷效（叶片压力面）
Figure 12. Overall cooling effectiveness at monitoring points in different working conditions （blade pressure side）
图 13 叶片吸力面综合冷效分布
Figure 13. Overall cooling effectiveness distribution of blade suction side
图 14 不同工况下监测点处综合冷效（叶片吸力面）
Figure 14. Overall cooling effectiveness at monitoring points in different working conditions （blade suction side）
图 15 气膜孔孔径变化对叶片综合冷效的影响
Figure 15. Effect of film hole diameter change on overall cooling effectiveness of blade
表 1 工况编号对应关系
Table 1. Corresponding relationship of working condition number
工况名称 工况编号 激光打孔加工叶片 Case 1 设计叶片 Design 喷涂涂层后的涂层堵孔叶片 Case 2 
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表 2 气膜孔孔径对应关系
Table 2. Corresponding relationship of film hole diameter
mm 工况 气膜孔孔径 Design 0.3 0.32 0.33 0.38 0.4 0.46 0.48 0.58 Case 1 0.32 0.35 0.35 0.4 0.41 0.49 0.5 0.6 Case 2 0.28 0.29 0.31 0.36 0.39 0.43 0.46 0.56
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表 4 不同工况下孔下游区域平均综合冷效
Table 4. Average overall cooling effectiveness of downstream area of hole in different working conditions
% 孔排
编号孔下游区域平均综合冷效η Case 1 Design Case 2 1 41.12 40.44 39.93 2 48.83 47.43 46.06 3 43.7 42.35 41.1 4 31.71 31.12 30.35 5 32.8 31.92 30.88 6 39.12 37.99 37.25 7 44.72 43.23 42.1 8 50.36 49.13 47.95 9 49.98 48.82 47.56 10 52.92 51.71 50.08 11 54.47 54.67 53.35 12 57.97 58.56 57.63 13 57.98 58.41 57.69
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