航空发动机损伤叶片再制造修复方法与实现

航空发动机叶片长期工作在高温、高压和高速的环境下,极易出现损伤。但是,损伤叶片的再制造修复技术一直被国外垄断,国内航空公司不得不花费大量的资金和时间将受损叶片送往国外维修。针对此问题,提出一种航空发动机损伤叶片再制造修复方法。首先,对损伤叶片进行失效特征分析,评价修复可行性;其次,获取并处理叶片点云数据,提取叶片截面的边界曲线,重建叶片数字化模型,通过布尔运算得到加工目标模型;再次,采用激光熔覆和自适应加工方法,对损伤叶片进行再制造修复;最后,分别对叶片三维数字化模型与实物进行精度检测和误差分析。结果表明,利用该方法建立的叶片数字化模型具有较好的精度和光顺性,再制造修复误差满足发动机维修手册的要求。

Method and implementation of remanufacture and repair of aircraft engine damaged blades

Aircraft engine blades are subject to damage because they are constantly exposed to high temperature, pressure and speed. Since the technology of repairing the damaged blades has been dominated by foreign companies, domestic airlines have to invest a tremendous amount of cost and time in having damaged blades repaired. This paper is to put forward a method in an attempt to remanufacture and repair damaged blades. Firstly, we evaluate the possibility of repairing the damage by analyzing the characteristics of damaged blades. Secondly, we acquire and process the point cloud of broken blades, extract the boundary curve of the blade section, reconstruct the 3D digital models of blades and obtain the 3D object model of blade via Boolean operation. Thirdly, we repair and remanufacture the damaged blades via laser cladding and adaptive machining. Finally, we check the precision of the 3D digital model and perform an error analysis. The results turn out that the proposed 3D digital model is of relatively greater accuracy and smoothness and remanufactured blade can meet the technical requirements prescribed in the aircraft engine maintenance manual.