Mechanism on thermal-strength comprehensive performance enhancement of novel film hole with rib and ball-shaped dimple
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摘要:
针对涡轮叶片气膜孔设计中普遍存在冷却与强度相矛盾的问题，全新提出了一种在孔进、出口处分别设有凸肋与球坑的结构方案。为探求新孔型的热强综合性能强化机理，以典型圆柱孔和簸箕孔为对比，建立了相同基准结构参数的仿真模型。在某发动机典型工况下，对各模型分别开展了仅流体域的和流热耦合的数值仿真。除了发现凸肋可削弱孔内旋涡，并将流量系数从圆柱孔的0.75增加至0.79以外，特别在传热上，证明球坑能够利用主流的入侵压迫二次流使其更贴体，从而使局部冷却效果由圆柱孔的0.41提高至0.47。沿用模型又开展了静强度仿真，揭示了凸肋和球坑结构通过钝化孔口尖劈，可使最大应力下降约一半。综合冷却和强度的仿真结果，基于DD6合金持久热强参数曲线进行概算，新方案的持久寿命分别增至了另两种孔的56.6倍和10.7倍，优势显著。
Abstract:Considering the prevalent contradiction between cooling and strength design of turbine blade film hole, a novel scheme utilizing rib and ball-shaped dimple at the hole inlet and outlet was proposed. To reveal the mechanism on thermal-strength comprehensive performance enhancement, two typical cylindrical and fan-shaped film holes were chosen as benchmarks. Simulation models of all three types with uniform basic structural parameters were also established. Fluid domain only and fluid-thermal coupling numerical simulations were conducted under a typical aero-engine working condition separately. The results indicated that the rib weakened the vortex inside the hole, thus the discharge coefficient increased from 0.75 of the cylindrical ones to 0.79. Especially in heat transfer, it was uncovered that the ball-shaped dimple induced the main flow’s intrusion and so enhanced the surface-attachment of the secondary flow. Thereby the local cooling effectiveness of 0.47 achieved, observably better than 0.41 of the cylindrical ones. The static strength simulations were further conducted following the identical models. The maximus stress was approximately reduced by half, since both the rib and dimple markedly blunted the sharp corners at the orifice edges. Integrating the simulation results of cooling and strength, the lives of the three schemes were estimated based on the creep-rupture curve of DD6 alloy. And the relative value of the novel film hole reached up to 56.6 and 10.7 times of the other ones, respectively, which showed a prominent advantage.
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图 3 流动和传热仿真计算域和边界条件
Figure 3. Flow and heat transfer simulation domains and boundary conditions
图 5 非绝热模型中截面流线及ξ分布云图
Figure 5. Streamlines and contours of ξ in middle sections of non-adiabatic models
图 6 非绝热模型三维流线及横截面上ξ分布云图
Figure 6. 3D streamlines and contours of ξ in cross sections of non-adiabatic models
图 7 非绝热模型涡核结构及横截面Ωx云图
Figure 7. Vortex cores and contours of Ωx in cross sections of non-adiabatic models
图 8 绝热模型横截面和中截面上$ \dot s $分布云图
Figure 8. Contours of $ \dot s $ in cross and middle sections of adiabatic models
表 1 球坑凸肋孔结构参数
Table 1. Structural parameters of film hole with rib and ball-shaped dimple
参数 数值 气膜孔孔径D/mm 0.5 壁厚L 3.6D 孔轴线与壁面夹角β/（°） 25.0 出口球坑 球面直径db_out 4.0D 球心与外壁面间距离jb_out 0.6D 球心与气膜孔轴线间距离lb_out 0.93D 边缘圆角半径Rb_out 0.6D 入口凸肋 截面圆直径db_in 3.5D 截面圆圆心与内壁面间距离jb_in 0.6D 边缘圆角半径Rb_in 0.6D 
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表 2 簸箕孔结构参数
Table 2. Structural parameters of fan-shaped film hole
参数 数值 轴向投影面扩张角γ/（°） 22.62 扩张段宽度of 1.66D 边缘圆角半径Rf 0.32D
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表 3 流动传热边界条件
Table 3. Boundary conditions of flow and heat transfer
位置 参数 数值 主流 入口 总压$p_1^* $/MPa 2.03 总温$T_1^* $/K 1 800 湍流度I1/% 5 出口 静压pb/MPa 1.82 二次流 入口 质量流量$\dot m_2 $/（g/s） 0.115 总温$T_2^* $/K 800 湍流度I2/% 1 吹风比M 1.01 固体域 内壁面 表面传热系数α/（W/（m2·K）） 2 200 参考温度Tref/K 800 物性
参数导热系数λs/（W/（m·K）） 22.3～33.2 比定压热容cp_s/（J/（kg·K）） 434 流体域 物性
参数导热系数λ/10−2 （W/（m·K）） 5.78～11.10 动力黏度μ/10−5 （N·s/m2） 3.63～6.07
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表 4 各网格数量下关注点的Tw
Table 4. Tw of monitor points with various mesh quantities
参数 网格单元数/104 430 607 1 307 关注点壁温Tw/K 1 313.7 1 336.1 1 332.6 壁温相对变化ΔTw/K 22.4 −3.5 壁温相对变化率ψ/% 2.36 0.37
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表 5 绝热模型中各型气膜孔的Cd
Table 5. Cd of various film holes in adiabatic models
气膜孔 圆柱孔（C） 簸箕孔（F） 球坑凸肋孔（B） Cd 0.75 0.90 0.79
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表 6 绝热模型中的$ {\dot{{{\boldsymbol{s}}}}}_{\bf{v}} $
Table 6. $ {\dot{{{\boldsymbol{s}}}}}_{\bf{v}} $ in adiabatic models
参数 圆柱孔（C） 簸箕孔（F） 球坑凸肋孔（B） 外流$ {\dot{{s}}}_{\text{v}{\_}\text{out}} $ 2.50 3.38（1.35） 2.96（1.18） 孔出口$ {\dot{{s}}}_{\text{v}{\_}\text{hole}} $ 0.25 0.61（2.42） 1.00（4.00） 合计$ {\dot{{s}}}_{\text{v}{\_}\text{tol}} $ 2.75 3.99（1.45） 3.96（1.44） 注：括号内为以圆柱孔为基准的相对比值。
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表 7 强度仿真结果
Table 7. Strength simulation results
位置 参数 圆柱孔（C） 簸箕孔（F） 球坑凸肋孔（B） 无孔区 $ \bar \varGamma $/MPa 100.0 100.0 100.0 入口 Γmax_in/MPa 684.0 637.0 291.7 Ξin 6.8 6.4 2.9 φin/（°） 25.0 25.0 77.4 出口 Γmax_out/MPa 684.0 649.5 491.5 Ξout 6.8 6.5 4.9 φout/（°） 25.0 25.0 77.6
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