Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades

Electrochemical machining (ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A math-ematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Further-more, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers.     

Numerical and experimental study of bleed impact in multistage axial compressors

In this study, the influence of inter-stage bleeding on the compressor performance and inter-stage flow field of a multistage axial compressor is investigated by both experimental and numerical methods. The experiment is conducted on a four-stage low-speed axial compressor, and a specific computational model is built to simulate the experiment environment accurately. To illuminate the fluid mechanisms of bleeding effect in detail, both the experiment and the simulation are carried out twice, i.e., in the first time, the mass flow rate upstream the bleed location is constant under different bleed rate conditions; while in the second time, the mass flow rate downstream the bleed location is constant under different bleed rate conditions. The results demonstrate that inter-stage bleeding has little influence on upstream compressor characteristics, and affects the upstream flow field only in the rear half of the stator. The bleed effect on the downstream flow field is embodied in the variation of an incoming flow profile, an increase as the compressor inlet flow coefficient decreases. Therefore, such an effect is only significant on compressor characteristics at small flow coefficient conditions. In multistage compressors, the variation of compressor characteristics and flow field caused by inter-stage bleeding is the comprehensive result of the bleeding and the variation of the upstream working condition. In addition, the comparison between numerical and experimental results shows that the flow moves towards top half of span through the downstream rotor passage in the numerical simulation, whereas the trend of flow field variation with different bleed rates at the outlet of the downstream rotor and stator is the same with that at the inlet of the downstream rotor in the experiment, which means that the numerical method has overestimated the radial mixing intensity of the flow.     

压气机引气模拟方法及引气结构的数值研究

为研究引气对于压气机设计的影响,以某高压压气机引气级为研究对象,通过对比源项引气模型与构建真实引气结构两种数值仿真方法的差异,并用构建真实引气结构的数值仿真方法分析了不同引气结构对压气机性能和流场的影响。仿真分析结果表明：两种数值仿真方法计算得到的压气机引气级的性能和局部流场均存在较大的差异,在压气机气动设计分析中应该采用构建真实引气结构的数值仿真方法。引气结构和主流道的夹角对主流区域叶尖位置的流场和压气机引气级的性能有较大影响,并且对引气管路内的流动分离程度也有较大影响,当此夹角为45°时,主流区及引气管路内的流动损失均最小。     

国内外航空发动机研制过程中评审工作的对比分析

评审是航空发动机研制过程中一个必不可少,至关重要的阶段,组织缜密、有效地评审对于降低研制风险、缩短周期、减少反复将起到不可或缺的作用.本文分别介绍了罗罗公司对某高压压气机技术方案的评审,和国内某发动机技术设计的评审.通过对评审人员的组成、评审内容和资料的准备以及评审结论、跟踪检查的对比,分析了两次评审在评审过程、评审机制等方面的差异.     

传热对叶尖间隙的影响

分析了影响叶尖间隙的诸因素，提出了计算瞬变状态下叶尖间隙变化的方法，并以某发动机为例，计算出一级压气机在不同工况下的隙量，给出间隙随时间变化的曲线图。     

基于混合遗传算法的压气机叶型自动优化设计

1引言遗传算法(Genetic A lgorithms,简称GA)是模拟生物在自然环境中的遗传选择和自然淘汰的进化过程而形成的一种全局优化概率搜索算法。遗传算法实施群体搜索,概率转移,不需要目标函数的导数信息,其全局搜索能力强,简单通用,适于并行处理,因而广泛应用于各种复杂系统的优化问     

压气机叶片的带平台圆弧形前缘

带平台圆弧形前缘的研究是为了优化前缘形状，抑制前缘流动分离。研究中使用了数值模拟方法和氢气泡流动显示实验方法。对带平台圆弧形前缘设计参数做了定义，并讨论了参数选择的准则。此前缘特有的双吸力峰的强度远远弱于圆弧形前缘的单吸力峰。在不同攻角下，其削弱前缘吸力峰，抑制流动分离的效果不亚于椭圆形(长短轴比=2)前缘，而且对加工精度要求低，更适合工程实际应用。     

边界层吹吸气对高负荷扩压叶栅性能的影响

采用边界层流动控制能够有效抑制扩压叶栅的流动分离。以某大弯折角低稠度扩压叶栅为研究对象,利用数值模拟手段研究了原型、叶片表面边界层单独吹气以及吹吸气相结合等边界层控制手段下的流场和叶栅性能变化情况。结果表明,无论是单独吹气还是吹吸气相结合的边界层控制方法,都能有效控制扩压叶栅中的边界层分离,从而较大幅度地增大叶栅负荷,并降低气动损失;计算表明,吹气和吸气的效果不尽相同,且吹吸气口位置及吹吸气流量对边界层的流动亦有较为明显的影响。其中采用1.7%的吹气流量,结合1.38%的吸气量,可以使静压增压比提高15%以上,而损失系数降低至原型的20%以内。     

基于RBF神经网络的压气机特性仿真

为克服传统仿真方法误差较大的问题，提出了一种基于RBF（多变量插值的径向基函数）神经网络的压气机特性仿真方法。利用RBF神经网络能逼近任意非线性系统的特点，对压气机特性进行了拟合。试验结果表明，此方法具有精度高，收敛速度快等优点，可广泛运用于发动机数值仿真及控制模拟等领域。     

带周向槽机匣处理的离心压气机扩稳机理分析

机匣处理能够改善压气机稳定裕度，扩大其稳定工作范围。通过对带周向槽机匣处理的NASA低速离心叶轮（LSCC）进行了时间精确的全三维数值模拟，并对周向槽机匣结构和实壁机匣结构在近失速流量点工况下的计算结果进行了比较分析。分析结果表明，周向槽处理机匣对叶顶间隙泄漏涡的抑制是周向槽机匣处理扩稳的主要原因。