载荷环境谱驱动的服役HPT叶片寿命混合预测方法

师利中; 张谦

doi:10.13224/j.cnki.jasp.20250318

载荷环境谱驱动的服役HPT叶片寿命混合预测方法

doi: 10.13224/j.cnki.jasp.20250318

师利中,
张谦

中国民航大学航空工程学院，天津 300300

详细信息

作者简介:
师利中（1984-），男，副教授，硕士，主要研究方向为飞机及发动机健康管理、智能诊断技术。E-mail：lzshi@cauc.edu.cn

中图分类号: V215.5；V232.4
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出版历程
- 收稿日期: 2025-07-07
- 网络出版日期: 2026-01-18

Load/environment spectrum driven hybrid life prediction approach for in-service HPT blades

College of Aeronautical Engineering，Civil Aviation University of China，Tianjin 300300，China

摘要

摘要:
针对航空发动机高压涡轮叶片在服役中疲劳寿命预测难的问题，编制应力和温度相关的服役载荷/环境谱，基于耐久性和损伤容限理论评估其低周疲劳寿命。基于流-热-固耦合仿真模型结合随机森林代理模型计算了叶片疲劳危险位置服役应力温度时间历程，通过多轴雨流计数方法编制载荷/环境谱。基于细节疲劳额定值法的半经验方法评估涡轮叶片裂纹萌生寿命。基于损伤容限理论和Franc3D平台构建物理模型计算涡轮叶片裂纹扩展寿命。结果表明：叶片疲劳危险位置为前缘根部气膜孔处，该处应力、温度预测误差分别为0.4%和0.71%，两者时序强相关，Pearson系数为0.902。建立的半经验-物理混合模型方法的预测寿命与真实叶片统计的平均寿命相比误差约为8%，可为航空发动机涡轮叶片寿命预测和维修间隔制定提供有价值的参考。
- 涡轮叶片 /
- 载荷-环境谱 /
- 裂纹萌生 /
- 裂纹扩展 /
- 疲劳寿命
Abstract:
To address the difficulty in predicting the fatigue life of aero-engine high-pressure turbine blades during service, a stress- and temperature-correlated service load/environment spectrum was developed. The blade low-cycle fatigue life was assessed based on durability and damage tolerance theories. The stress-temperature time histories at critical fatigue locations were computed using a fluid-thermal-structural coupled simulation model combined with a random forest surrogate model. The load/environment spectrum was compiled via the multiaxial rain-flow counting method. The crack initiation life was evaluated using a semi-empirical approach based on the detail fatigue rating method. The crack propagation life was calculated by constructing a physical model on the Franc3D platform grounded in damage tolerance theory. The results demonstrated that the critical fatigue location of the blade was at the film-cooling hole near the leading-edge root. At this location, the prediction errors for stress and temperature were 0.4% and 0.71%, respectively, and their time histories exhibited a strong correlation, with a Pearson coefficient of 0.902. The established semi-empirical-physical hybrid model predicted the blade life with an error of about 8% compared with the average statistical life of actual blades. This approach could provide a valuable reference for predicting the life of aero-engine turbine blades and determining maintenance intervals.
- turbine blade /
- load/environment spectrum /
- crack initiation /
- crack propagation /
- fatigue life

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图 1 叶片寿命划分方法

Figure 1. Blade life classification method

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图 2 叶片寿命计算流程

Figure 2. Blade life calculation process

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图 3 叶片和流体域模型

Figure 3. Blade and flow field model

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图 4 网格无关性分析结果

Figure 4. Mesh independence analysis results

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图 5 Von-Mises等效应力分布云图

Figure 5. Von-Mises stress distribution contour map

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图 6 温度分布云图

Figure 6. Temperature distribution contour map

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图 7 气膜孔Von-Mises等效应力分布

Figure 7. Von-Mises stress distribution in film cooling hole

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图 8 代理模型建模流程

Figure 8. Surrogate model development flowchart

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图 9 代理模型测试结果

Figure 9. Surrogate model testing results

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图 10 应力和温度时序

Figure 10. Stress and temperature time series

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图 11 应力温度重构序列

Figure 11. Stress-temperature reconstruction sequence

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图 12 裂纹扩展速率参数

Figure 12. Crack propagation rate parameters

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图 13 裂纹扩展仿真流程图

Figure 13. Crack propagation simulation flowchart

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图 14 前缘扩展模型示意图

Figure 14. Leading edge expansion model schematic

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图 15 裂纹前缘应力强度因子

Figure 15. Stress intensity factor at the crack tip

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图 16 裂纹前缘扩展形貌

Figure 16. Morphology of crack tip propagation

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图 17 裂纹扩展寿命曲线

Figure 17. Crack propagation life curves

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图 18 疲劳寿命计算结果

Figure 18. Fatigue life calculation results

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表 1 材料相关属性

Table 1. Material-related properties

温度T/K	弹性模量 E/GPa	切变模量 G/GPa	泊松比μ
523.15	168	66.5	0.26
773.15	161.5	63.5	0.27
873.15	151.5	59.5	0.27
1073.15	139.5	52.5	0.29

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表 2 稳态边界条件

Table 2. Steady-state boundary conditions

参数	数值
转速/（rad/s）	1581.9
进口燃气温度/K	1604.9
进口冷气温度/K	791.15
进口压强/kPa	1310.8
出口压强/kPa	593.9
冷气流量/（kg/s）	0.1

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表 3 载荷/环境谱

Table 3. Load/environment spectrum

循环编号	应力/MPa		温度/K （峰值）
循环编号	峰值	谷值	温度/K （峰值）
1	678.97	548.12	723.46
2	706.69	553.31	779.52
3	754.07	548.97	766.82
4	725.73	576.69	850.60
5	783.8	539.45	854.08
6	804.86	568.87	956.36
7	825.38	488.58	938.17
8	678.04	461.4	933.21
9	547.19	423.85	847.65
10	699.72	573.2	895.66
11	875.94	710.71	937.32
12	884.61	768.78	922.30
13	896.46	102.92	919.12

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表 4 裂纹扩展速率参数拟合公式

Table 4. Fitting formula of crack growth rate parameters

参数	拟合公式
C	7.0678×10⁻⁹exp（−1680/T）
m	3.4953+1.2468×293/T

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表 5 维修手册裂纹型损伤极限长度规定

Table 5. Damage limit for crack-type in repair manual

损伤区域		损伤容许极限长度/mm
叶片前缘	A区	2
	B、C区轴向	1.2
	B区径向	1.5
	C区径向	0.7

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