A springback along the chord-wise direction is occurred in the rolling process of the high pressure compressor blade in aero-engine, which affects the accuracy of the blade profile directly and then affects the service performance of the engine. In order to achieve the net-shape of the compressor blade for the aero-engine by rolling, an optimized designing method is presented to improve the accuracy of rolling cavity surface by mapping transformation of the section curves, which compensated the springback on the original section contours. The deformation of the sheet metal in bending process is analyzed, and a model which described the variation of central angle before and after springback is studied. After that, a springback compensation method for blade section is proposed and the springback deviation of every process model's section curve is compensated. The springback compensated section curves are mapped to a sector in three dimension around the rollers' axes, and the rolling cavity surfaces are reconstituted through the mapped section curves. An effective numerical calculation method is used to simulate the blade rolling process by both the original cavity surfaces and the springback compensated cavity surfaces in order to obtain the shapes of corresponding deformed blades. The results show that the optimal designing of mold cavity can improve the precision of compressor blade profile effectively, and that the deviation of the deformed blade is decreased to 16.7% comparing with the original results. The springback compensating method, which provides a theoretical foundation for designing roller cavity surfaces, would contribute to achieving the net shape profile of the rolling compressor blade. Meanwhile, the method offers a foundation for improving the precision of the irregular sheet metal in plastic deformation.
[1] 柳万珠,陈贵林,梁忠效,等. 压气机转子叶片类零件的制造与修复技术[J]. 航空制造技术, 2010(22):36-39. LIU Wanzhu, CHEN Guilin, LIANG Zhongxiao, et al. Manufacturing and repair technology for compressor rotor blade[J]. Aeronautical Manufacturing Technology, 2010(22):26-31.
[2] 王辉,吴宝海,李小强. 新一代商用航空发动机叶片的先进加工技术[J]. 航空制造技术, 2014(20):26-31. WANG Hui, WU Baohai, LI Xiaoqiang. Advanced machining technology of new generation commercial aeroengine blade[J]. Aeronautical Manufacturing Technology, 2014(20):26-31.
[3] 陈福兴,张秋菊. 基于UG的叶片型面质量评估[J]. 工具技术, 2006, 40(8):66-69. CHEN Fuxing, ZHANG Qiuju. Evaluation of blade surface quality based on UG[J]. Tool Engineering, 2006, 40(8):66-69.
[4] 孙振忠,杨玉英. 柱面扁壳面畸变形成机理及控制[J]. 机械工程学报, 2005, 41(5):210-214. SUN Zhenzhong, YANG Yuying. Generating mechanism and controlling technique on surface deflection of cylinder shallow shells[J]. Chinese Journal of Mechanical Engineering, 2005, 41(5):210-214.
[5] ZHANG D, LI Y, LIU J, et al. A novel 3D optical method for measuring and evaluating springback in sheet metal forming process[J]. Measurement, 2016, 92:303-317.
[6] XIONG W, GAN Z, XIONG S P, et al. Rapid springback compensation for age forming based on quasi Newton method[J]. Chinese Journal of Mechanical Engineering, 2014, 27(3):551-557.
[7] PANTHI S K, RAMAKRISHNAN N, AHMED M, et al. Finite element analysis of sheet metal bending process to predict the springback[J]. Materials & Design, 2010, 31(2):657-662.
[8] SALHI S E, COENEN F, DIXON C, et al. Predicting "springback" using 3D surface representation techniques:A case study in sheet metal forming[J]. Expert Systems with Applications, 2015, 42(1):79-93.
[9] LIU Y, LIU J, HU P, et al. Quantitative prediction for springback of unload and trimming in sheet metal stamping forming[J]. Chinese Journal of Mechanical Engineering, 2003, 16(2):190.
[10] 李光耀,王琥,杨旭静,等. 板料冲压成形工艺与模具设计制造中的若干前沿技术[J]. 机械工程学报, 2010, 46(10):31-39. LI Guangyao, WANG Hu, YANG Xujing, et al. Some new topics on process design and mould Manufacture for sheet metal forming[J]. Journal of Mechanical Engineering, 2010, 46(10):31-39.
[11] 杨伟俊,李东升,李小强,等. 基于快速回弹补偿的橡皮囊液压成形模面设计方法[J]. 机械工程学报, 2011, 47(12):67-73. YANG Weijun, LI Dongsheng, LI Xiaoqiang, et al. Tool surface design method with rapid springback compensation for fluid cell forming process[J]. Journal of Mechanical Engineering, 2011, 47(12):67-73.
[12] 刘迪辉,吴磊,李光耀,等. 任意截面线回弹理论计算方法及应用[J]. 锻压技术, 2009, 34(6):143-147. LIU Dihui, WU Lei, LI Guangyao, et al. Theoretical calculation method and its application of arbitrary section springback[J]. Forging & Stamping Technology, 2009, 34(6):143-147.
[13] 甘忠,熊仕鹏,朱加赞,等. 铝合金整体壁板时效成形模具型面构造[J]. 机械工程学报, 2012, 48(16):74-79. GAN Zhong, XIONG Shipeng, ZHU Jiazan, et al. Structure of tool surface for age forming of integral panel of aluminum alloy[J]. Journal of Mechanical Engineering, 2012, 48(16):74-79.
[14] 陈雅, 周红梅. 冷轧成形整流叶片毛边问题分析及改进方案[J]. 模具技术, 2014, 5(12):23-30. CHEN Ya, ZHOU Hongmei. Analysis and improvement plan for the straightener blade burrs in cold rolling process[J]. Mould Technology, 2014, 5(12):23-30.
[15] 王渊彬,汪文虎,张艳,等. 压气机叶片辊轧模具型腔快速建模技术[J]. 航空学报, 2014, 35(11):3190-3198. WANG Yuanbin, WANG Wenhu, ZHANG Yan, et al. Rapid modeling technology of rolling mold cavity of aero-engine compressor blade[J]. Acta Aeronautica et Astronautica Sinica, 2014, 35(11):3190-3198.
[16] 靳淇超,汪文虎,蒋睿嵩,等. 一种改进的压气机叶片辊轧成形前滑计算模型[J]. 航空学报, 2016, 37(10):3178-3185. JIN Qichao, WANG Wenhu, JIANG Ruisong, et al. An improved calculation model for forward slip in rolling compressor blade[J]. Acta Aeronautica et Astronautica Sinica, 2016, 37(10):3178-3185.
[17] 靳淇超,汪文虎,蒋睿嵩,等. 压气机叶片辊轧模具型腔前滑补偿方法[J]. 航空学报, 2017, 38(1):323-332. JIN Qichao, WANG Wenhu, JIANG Ruisong, et al. Researching forward slip compensation method for designing roller mold cavity of compressor blade[J]. Acta Aeronautica et Astronautica Sinica, 2017, 38(10):323-332.
[18] KAGZI S A, GANDHI A H, DAVE H K, et al. An analytical model for bending and springback of bimetallic sheets[J]. Mechanics of Advanced Materials and Structures, 2016, 23(1):80-88.
[19] CAI Z Y. Precision design of roll-forging die and its application in the forming of automobile front axles[J]. Journal of Materials Processing Technology, 2005, 168(1):95-101.
[20] JIANG Ruisong, WANG Wenhu, ZHANG Dinghua, et al. A practical sampling method for profile measurement of complex blades[J]. Measurement, 2016, 81:57-65.
