Study on Titanium Alloy TC4 Ballistic Penetration Resistance Part I:Ballistic Impact Tests

Ballistic impact test of different-scale casings is an efficient way to demonstrate the casing containment capability at the preliminary design stage of the engine. For the sake of studying the titanium alloy TC4 casing performance, the ballistic tests of flat and curved simulation casing are implemented by using two flat blades of different sizes as the projectile. The impact mechanism and failure of the target are discussed. Impact of the projectile is a highly nonlinear transient process with the large deformation of the target. On the impact, failures of the flat casing and the subscale casing are similar, concluding two parts, the global dishing and localized ductile tearing. The main localized failure mode combines plugging (shear) and petaling (shear) if the projectile perforates or penetrates, while crater (shear) if the projectile rebounds. The ballistic limit equation is verified by the test data and the results show that this empirical equation could be a practical way to estimate the critical velocity.     

多层机匣的包容性数值仿真研究

采用瞬态非线性有限元分析方法对多层机匣的包容性进行了数值仿真研究,对比分析了不同层数机匣在相同撞击条件下的位移、塑性应变和能量的变化,以及同层数机匣有间隙与无间隙时的包容情况。仿真结果表明：同厚度的不同层数机匣,层数越多包容效果越好;对于同层数机匣,层间无间隙机匣的包容效果优于有间隙机匣的。     

面向包容性的航空发动机机匣研究综述

机匣作为航空发动机的关键部件,其包容性能是保障飞行安全的必要条件。针对机匣包容性问题,首先,简要介绍涉及包容性的机匣类别和结构形式;其次,从理论研究、仿真分析及试验测试等方面概述机匣的冲击响应、损伤机理和包容性能等,简述机匣包容性试验方法及试验研究进展,按机匣材料类别对包容性数值仿真研究分类介绍;最后,总结机匣包容性研究状况并从机匣工作条件、受载情况和优化设计角度对机匣包容性研究进行展望。     

Characteristics and mechanisms of turboshaft engine axial compressor casing containment

To investigate the containment characteristics and mechanisms of axial compressor blade and casing in turboshaft engine, experimental and simulation research is conducted on Titanium alloy axial compressor blades and stainless steel simulator casings in this paper. Experiments for four thicknesses (from 0.8 mm to 1.4 mm) of casings are presented on high-speed spin tester. Perforation, ricochet with and without failure of the casings are obtained in test results. Three obvious bulges or dishing region are observed, petaling failure occurs in the first bulge or the third deformation region. Parabolic and elongated dimples are observed at the fracture surface. Finite Element (FE) models with calibrated Johnson-Cook material behavior law are built and analyzed by using explicit dynamic software for a better understanding on the containment behavior. Good agreement is obtained between the experimental observations and numerical predictions. The evolution of the impact force, energy absorption, temperature increase and the cracks’ propagation are analyzed. Three force peaks occur in the impact process. Energy analysis reveals that penetration condition of ricochet with failure leads to most internal energy of the casing.     

Failure mechanisms of bolted flanges in aero-engine casings subjected to impact loading

In this paper, a failure evaluation criterion was proposed for the bolted casing-flange structure under impact loading. Subsequently, ballistic tests with eighteen bolted casing-flange structure specimens were conducted to validate the failure evaluation criterion. Parameter studies were then carried out using the validated FE models. Both the experimental and numerical results demonstrated the accuracy of the failure evaluation criterion. The failure evaluation criterion provided a quick and easy way to determine the failure mode of the casing connection area by using the materials and dimensions of the structure. Based on the failure evaluation criterion, designing the structural failure mode of the bolted casing-flange structure to be between flange failure and bolt failure can improve the impact resistance of the connection area of the aero-engine casings. This investigation revealed that the impact failure is not the unique criterion in evaluating the containment of the casing connection area, structural failure should also be involved in the evaluation criteria.     

基于打靶试验的风扇机匣包容能力评估方法

为保障飞行安全,航空发动机机匣需具有足够的抗冲击能力以包容高速旋转状态下丢失的叶片。针对某型涡扇发动机对开式风扇机匣包容性评估需求,提出了1种结合真实机匣打靶试验和有限元分析评估机匣包容能力的方法。通过使用真实机匣和真实叶片进行打靶试验获得风扇机匣的冲击损伤情况,并基于ANSYS/LS-DYNA进行了瞬态动力学有限元分析。结果表明:采用Johnson-Cook模型预测的机匣伤形状、尺寸以及叶片残余速度均与试验结果接近,验证了数值分析方法的准确性。采用验证过的数值分析方法开展旋转状态下机匣的包容性评估,发现由于撞击姿态差异和失效模式转变,风扇机匣可以包容以100%工作转速飞出的叶片,但机匣出现长裂纹,接近临界包容状态。所提出的方法可以在不具备部件包容试验条件的情况下,以较方便的形式对机匣包容能力可靠评估。     

带有安装边螺栓连接结构的机匣包容能力研究

为了研究带有安装边螺栓连接结构的机匣对断裂叶片的包容能力,截取环形机匣中的安装边螺栓连接结构,开展有限元仿真和冲击试验。首先,使用LS-DYNA软件建立有限元模型,研究撞击角度、撞击位置、定距套和止口对机匣安装边螺栓连接结构抗冲击能力的影响。仿真结果表明：撞击位置、撞击角度、定距套和止口都对结构的抗冲击能力有显著的影响,当叶片撞击在单侧机匣的安装边位置时结构的抗冲击能力最弱,定距套和合理的止口设计都能够有效提高结构的抗冲击能力。然后,通过机匣安装边螺栓连接结构的抗冲击试验,验证了数值仿真方法的准确性和可靠性,为数值仿真结论的有效性提供了依据。最后,通过数值仿真分析了螺栓断裂过程,并结合试验分析揭示了螺栓发生剪切断裂和拉伸断裂的原因。     

平板条叶片侵彻靶板的动响应研究

为了研究真实航空发动机机匣的包容性,对平板条叶片以不同初始速度撞击矩形靶板的侵彻机理进行了数值仿真研究。通过分析撞击过程中叶片加速度、速度、位移的变化,了解了与试验相符的撞击、变形、撕裂和失效过程。利用有效的数值模型验证了叶片初始速度与残余速度之间的关系满足Recht-Ipson公式,且工程中常用的破坏势能法可用于初步预测残余速度。     

Containment of soft wall casing wrapped with Kevlar fabric

Aramid fabrics have been commonly used in the civil turbofan engine fan blade containment system for its excellent performance. To investigate the behavior and capability of soft wall containment casing, a series of fan blade released tests were conducted on the high-speed spin tester.The soft wall casing was fabricated by wrapping multiple layers of Kevlar49 plain woven fabric around a thin steel ring. Casings with different inner metal ring and outer fabric layers number were compared. The method of using the explicit dynamic software LS-DYNA to establish the finite element analysis model for the quantitative analysis of the containment process was developed and conducted. The simulation results are in good agreement with the test results. It is shown that the containment process of the soft wall casing can be divided into three impact stages. The casing with low-stiffness inner metal ring will get severe overall deformation and lose the structural integrity when it suffers the blade impact. Kevlar fabric layers will appear large bulge on outside surface and absorb the most impact dynamic energy of the high speed released fan blade. By summing up the results of the test and simulation, an empirical critical equation was derived to describe the relationship between the released blade dynamic energy and the Kevlar fabric thickness.     

转速对高速旋转冲压增程弹用进气道影响数值模拟

结合分区对接网格技术以及二阶精度区域分解算法，对高速旋转、含侧向支柱冲压增程弹丸进气道内外复杂流场进行了数值模拟。得到了高速旋转工况下对应于不同来流攻角和旋转角速度，临界工况时，超声速进气道内外流场复杂的波系结构。随着旋转角速度的提高，进气道总压恢复系数和动能效率均有所降低，而流场畸变指数则显著增大。特别是当转速达到20kr／min，进气道总压恢复系数和动能效率下降趋势以及流场畸变指数增大趋势更明显。攻角的存在对冲压发动机进气道的总体性能产生了负面影响。     

环形编织层板冲击包容数值模拟

为分析航空发动机复合材料机匣对破断叶片的包容,采用有限元仿真方法开展了计算研究。通过旋转体与机匣冲击破坏过程的计算,确定机匣的包容能力。基于具备显式求解功能的商用有限元软件Abaqus/Explicit,采用3维实体单元网格,将2维3轴编织的碳纤维层合材料简化成连续的正交各向异性材料,通过软件提供的Vumat用户子程序接口编写Fortran代码定义材料模型,计算与转轴分离后的模拟断裂叶片对机匣的冲击过程。通过冲击后的临界转速和能量吸收数据,比较了模拟计算与实物旋转冲击模拟试验的结果,二者具有较大的可比性。虽然计算中还缺乏材料基本性能表征的理想数据,但在多种工况下仿真计算表明模拟结果稳定,有望成为复合材料包容分析实用有效的方法。     

双层模型机匣和叶片的包容性问题数值模拟

采用显式动力分析有限元技术,研究了飞断叶片模型与机匣模型的撞击过程,并且计算了不同类型机匣模型包容情况下的临界转速。计算结果表明,双层机匣模型的包容能力明显地优于单层机匣模型,间隙情况对双层机匣模型的包容能力有一定的影响。研究结果对多层航空发动机机匣的包容性设计有一定的参考价值。     

机匣造型设计对涡轮叶尖泄漏流损失的影响

针对带叶尖间隙的T106高负荷低压涡轮叶栅,基于耦合了Langtry-Menter转捩模型的Menter's SST (shear stress transport)两方程模型,数值研究了涡轮叶片全机匣造型和部分机匣造型对叶尖泄漏损失的影响.计算结果表明:机匣造型设计的引入重新组织了叶尖区域内的涡系结构及损失成分,且这一改变明显受到机匣造型圆弧高度的影响;叶尖间隙内靠近压力面分离泡的展向尺度增大,分离泡形成的堵塞效应降低了叶尖泄漏流动能;而部分机匣造型处理可以缓解叶片通道内因局部扩张而引起的横向流动,使得出口展向损失减小区域进一步扩大,从而造成叶栅出口损失的明显下降;相对原始机匣,最大降幅可达6.1%.间隙敏感性分析表明,两种机匣造型在一定的间隙范围内能够有效降低叶尖泄漏流损失,而且部分机匣造型具有更宽的有效间隙范围和更大损失减小量.      

Design and development of a five-axis machine tool with high accuracy,stiffness and efficiency for aero-engine casing manufacturing

In order to satisfy the machining requirements of aero-engine casing in modern aviation industry, this paper investigates three main issues during the design and development process of a five-axis machine tool with high accuracy, stiffness and efficiency, including whole structure design,key components design, and supporting stiffness design. First, an appropriate structure of five-axis machine tool is determined considering the processing characteristics of aero-engine casing. Then, a dual driv...     

耦合进排气壳的增压器涡轮流动干扰及激振力弱化研究

为探究船用增压器涡轮在耦合进排气壳条件下的流动特性,采用SST湍流模型和FFT方法对某增压器轴流涡轮与进排气壳耦合的流场进行非定常数值模拟,重点分析排气壳非对称流场对涡轮动叶片压力的干扰特性和扰动来源,在此基础上提出基于导叶非对称布局的激振力弱化改型方案并进行了验证。结果表明：进气壳影响静叶前缘静压沿周向的分布,排气壳流场导致的非对称背压会给动叶表面造成低频的压力波动,约为3.6%的转子通过频率,在尾缘吸力面处该低频波动幅值大于动静叶排干涉导致的高频波动幅值;排气壳内部复杂的分离流动和涡系结构是产生上述流动干扰的主要原因。4种非对称布局方案都能在几乎不影响涡轮性能的前提下分散并弱化高频波动幅值;其中Case2尾缘高频幅值减小了98.6%,低频幅值减小了52.6%,而且涡轮效率还有略微提高,为最优布局。     

放电电阻对等离子合成射流激励器特性的影响

设计了一种射流出口为竖直圆孔的等离子体合成射流激励器(PSJA),旨在研究在不同放电电阻时激励器的特性。实验中通过电参数测量、高速纹影观察获得了放电电阻为300、200、100 Ω的激励器放电特性及瞬态流场特性。结果表明:放电过程由于限流电阻的存在,可分为两个阶段,即急剧放电阶段和缓慢放电阶段。这一模式在满足较高初始能量注入的同时可以持续为激励器提供能量,有效提高了稳定性。同时,观察到较小的放电电阻,可以获得较大的射流速度,流动控制能力更强。但减小放电电阻,会导致放电电流增大,射流速度不稳定,工作稳定性变差。在实际应用中,需要综合考虑并确定最终的电阻值,确保两个放电阶段能量的合理分配。      

基于气动分离技术的弹丸弹托分离仿真

为了研究气动分离技术使弹丸弹托分离的情况,对其进行了模拟仿真研究。采用气动分离技术使弹丸弹托分离,基于气体动力学与摩擦力学理论,分别建立了弹托绕流模型与弹丸弹托气动分离模型。使用Fluent进行绕流仿真,得到了不同速度下弹托分离前后状态下的阻力系数,再用Simulink对54式12.7mm穿甲燃烧弹的弹丸和弹托进行分离仿真,得到了弹丸弹托分离过程的特征结果。结果表明,利用气动分离技术可以使弹托和弹丸较好地分离。上述研究为弹丸和弹托的研发、使用提供了有益的参考。     

NASA 二级轻气炮设备简介

随着人类航天活动日益频繁,地球轨道上空间碎片总数逐年增长。航天器表面空间碎片防护工作受到各航天大国的高度重视。航天器针对毫米级空间碎片主要采用被动防护方式。超高速撞击实验是防护方案设计工作的基础。NASA 在毫米级弹丸超高速撞击实验中采用的主要发射装置为二级轻气炮。本文对美国 NASA 和相关单位二级轻气炮设备及其未来发展趋势进行简要介绍,同时对我国相关单位超高速撞击实验设备进行分析,并对发展趋势进行讨论。     

多级轴流压气机机匣处理级的探讨

本文提出了一种确定多级轴流压气机机匣处理级的新方法。首先,预测多级轴流压气机各级的级极限负荷,依此确定旋转失速发生时率先失速的级并得到实验证实;其次,将率先失速级作为待处理的级,并在一亚音速双级轴流压气机实验台上针对四种不同型式的机匣处理,进行了较为系统的实验验证。实验结果证实在率先失速级上进行机匣处理会取得很好的扩稳效果,用级极限负荷来确定多级轴流压气机机匣处理级的方法具有广阔的应用前景。     

机匣包容性破坏势能法的试验验证

为了验证航空发动机机匣包容性破坏势能法，本文完成了20次模型机匣包容性冲击试验，得到了模型叶片撞击模型机匣时的速度、应变响应和模型叶片撞击模型机匣过程的高速摄影照片。试验结果表明，该模型机匣的非包容失效模式主要是剪切破坏。本文还采用数值分析方法对机匣包容性进行了模拟，计算结果与试验结果吻合良好。