New technologies for manufacturing steam turbines. Production of parts for a locomotive diesel engine turbocharger using Delcam software products. Development of technology for manufacturing a mold displacer for casting a wax model

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Introduction

Brief description of TNA RD-180.

Chapter 1. Technological part

1.1 Operating conditions of the TNA turbine blade

1.2.3 Mechanical properties of the material (at T = 20 °C)

1.2.4 Heat treatment

1.4.1 Material utilization rate

1.6.1 Types of manufacturing diamond rollers

1.6.2 Tolerances

1.6.3 Design

1.6.4 Grit

1.6.5 Diamond grade -- D 711 A

1.6.7 Initial production and calculation of a new diamond roller for dressing

1.6.8 Operation

1.6.9 Axes arrangement

1.6.10 Processing modes

1.7 Selecting bases and justifying the sequence of part processing

1.8 Calculation of allowance for machining in operation No. 12.

1.9 Cutting modes

1.10 Rationing

Chapter 2. Design part

2.1 Description of the device

2.2 Calculation of fixture for clamping force

Chapter 3. Research part

3.1 Basics of the hydro shot peening process

3.2 Technology of the hydro-shot peening process

3.2.1 Design and operation of the installation for hydro-shot peening

3.2.2 Technological requirements for the process

3.2.3 Processing order

3.2.4 Hardening control

3.3 Determination of residual stresses

3.4 Fatigue testing of blades

3.4.1 Purpose of testing

3.4.2 Test object - turbine blades

3.4.3 Study of natural frequencies.

3.4.4 Blade fatigue test equipment

3.4.5 Study of relative stress distribution

3.4.6 Fatigue test method

3.4.7 Test results processing method

3.5 Test results.

Chapter 4. Automation part

4.1 Description of the CATIA software package

4.1.1 Applications and capabilities of CATIA

4.1.2. Description of modules of the CATIA software package

4.2 Basic functions of building a model and drawing of parts in CAD CATIA.

4.2.1 User interface

4.2.2 Creating 2D geometry, dimensioning and labeling

4.2.3. Creating a three-dimensional model of a part and constructing two-dimensional geometry based on it

4.3 Construction of a model of a TNA turbine blade.

Chapter 5. Industrial ecology and production safety.

5.1 Analysis of the technological process of manufacturing a gas turbine blade. Determination of the main impacts on the environment and human health. Development of protective measures.

5.1.1 Analysis of the technological process for manufacturing a gas turbine blade.

5.1.2 Analysis of harmful effects on the environment and development of protective measures when performing creep feed grinding operations.

5.1.3 Analysis of harmful effects on human health and development of protective measures when performing creep feed grinding operations.

5.2 Analysis and calculation of workplace illumination.

5.2.1 Analysis of workplace illumination

5.2.2. Calculation of illumination of the workplace

5.3 Ventilation of the production area.

5.4 Fire protection measures.

5.5 Conclusions based on the results of the analysis of harmful and dangerous factors

Chapter 6. Calculation of the economic efficiency of introducing a new technological process

6.1 Calculation of costs for the design of the technological process for manufacturing a TNA turbine blade

6.1.1 Calculation of costs for the design of the technological process for manufacturing a TNA turbine blade in the designed version

6.1.2 Calculation of costs for designing the technological process for manufacturing a TNA turbine blade in the basic version

6.2 Calculation of the annual economic effect from the introduction of a new technological process

6.2.1 Material cost calculation

6.2.2 Salary expenses

6.2.3 Space costs

6.2.4 Calculation of equipment operating costs

6.2.5 Calculation of energy costs

6.2.6 Calculation of the cost of technical processes and the economic effect of implementation

6.3 Calculation of payback time for introducing a new technological process

6.3.1 Calculation of investment in equipment

6.3.2 Calculation of costs for the development of new technology

6.3.3 Calculation of the payback time for introducing a new technological process.

Chapter 7. Conclusions on the work

Chapter 8. Literature and other sources

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In this thesis project, the technological part (first section) examines the technical process for producing a working uncooled gas turbine blade. Also in the first section, the working conditions of the part in the assembly, the method of obtaining the workpiece are described, the characteristics of the material of the TsNK-7P blade are given, an analysis of manufacturability is carried out, the choice of bases for machining is described, the allowance for processing the intermediate technological base is calculated, and the standardization of creep feed grinding operations is carried out. The technological part describes in detail the method of mechanical processing - creep-feed grinding and diamond dressing tools. In the design part, a device for fastening a part when processing the blade shank is considered, and the screw clamp force for this device is calculated. The research part examines the process of hydro-shot blasting hardening of a blade lock: the essence of the process, the design of a hydro-shot blasting installation, the method for determining residual stresses in the surface layer and fatigue testing of the part are described. In the part on automation, the CATIA software package, its application in industry, and software products of this package are considered. The process of constructing two-dimensional and three-dimensional geometry and the process of creating a blade model in the CATIA design automation system are also considered. . In terms of labor protection, measures have been developed to improve production safety and environmental protection. In the economic part, the efficiency of implementing this blade production process in relation to the previous one was calculated.

Introduction

One of the most complex mechanical engineering structures is the gas turbine.

The development of gas turbines is determined, first of all, by the development of aviation gas turbine engines for military purposes. In this case, the main thing is to increase specific thrust and reduce specific gravity. Economic and resource problems for such engines are secondary.

One of the most loaded parts that limit the time between overhauls is the uncooled turbine blades, made of wrought nickel alloy EI893. Due to limitations in long-term strength, blades made from this alloy have a service life of 48,000 hours. Currently, there is quite high competition in the production of turbine blades, so the issues of reducing cost and increasing the service life of blades are very relevant.

This graduation project examines a relatively new technology for the domestic industry for the production of long-length uncooled turbine blades (more than 200 mm). As a blade blank, a casting from the TsNK-7P material is used without allowance for mechanical processing of the blade, subjected to hot isostatic pressing. To reduce the labor intensity of blade manufacturing, deep-feed grinding of the lock is used, and to increase fatigue resistance, the blade lock after grinding is subjected to hydro-shot peening.

This graduation project examines the production technology of a turbine blade. Since this technical process is universal for blades of various sizes, it can be used both for the manufacture of low-pressure turbine blades of a gas turbine engine (or gas turbine engine) and a turbocharger turbine of a liquid propellant rocket engine. This work examines the blade for the fuel pump of the RD-180 liquid-propellant rocket engine. However, due to the versatility of the blade material and technological process, we also pay increased attention to the service life of the product. The process of creep-feed grinding for parts made of heat-resistant alloys, such as a turbine blade, is examined in detail, and the production technology and properties of diamond rollers used in creep-feed grinding for dressing grinding wheels are described. The project is designed for the accuracy and clamping force of the “pike mouth” device, which is widely used in creep-feed grinding operations in the blade production process. The research part examines the process of increasing fatigue strength by blasting the blade lock with shot in a liquid medium (hydro-shot peening), and describes methods for determining residual stresses and conducting fatigue tests of the blade. The work also describes the CATIA design automation system and the creation of a part model and design documentation in this system. In terms of labor protection, measures have been developed to improve production safety and environmental protection. The efficiency of implementing this blade production process in relation to the previous one was also calculated.

Brief description of TNA RD-180.

*Description is given without a gas generator.

The turbopump unit is made according to a single-shaft design and consists of an axial single-stage jet turbine, a single-stage centrifugal screw oxidizer pump and a two-stage centrifugal screw fuel pump (the second stage is used to supply part of the fuel to gas generators).

On the main shaft with the turbine there is an oxidizer pump, coaxially with which two stages of the fuel pump are located on another shaft. The shafts of the oxidizer and fuel pumps are connected by a gear spring to unload the shaft from thermal deformations that arise as a result of the large temperature difference between the working bodies of the pumps, as well as to prevent freezing of the fuel.

To protect the angular contact shaft bearings from excessive loads, effective auto-unloading devices are used.

The turbine is an axial single-stage jet turbine. To prevent fire due to breakdowns of structural elements or friction of rotating parts against stationary ones (due to the selection of gaps from deformations or work hardening on the mating surfaces from vibration), the gap between the blades of the nozzle apparatus and the rotor is made relatively large, and the edges of the blades are made relatively thick.

To prevent fire and destruction of turbine gas path parts, nickel alloys are used in the design, including heat-resistant ones for hot gas lines. The turbine stator and exhaust tract are forcibly cooled with cold oxygen. In areas of small radial or end clearances, various types of heat-protective coatings are used (nickel for the rotor and stator blades, metal-ceramic for the rotor), as well as silver or bronze elements, which prevent fire even if there is a possible contact with the rotating and stationary parts of the turbopump unit.

To reduce the size and mass of foreign particles that could lead to a fire in the gas path of the turbine, a filter with a cell of 0.16 * 0.16 mm is installed at the engine inlet.

Oxidizer pump. The high pressure of liquid oxygen and, as a result, an increased risk of fire determined the design features of the oxidizer pump.

Thus, instead of floating sealing rings on the impeller collars (usually used on less powerful pumps), fixed gap seals with a silver lining are used, since the process of “floating” of the rings is accompanied by friction at the points of contact of the impeller with the housing and can lead to fire of the pump.

The screw, impeller and torus outlet require particularly careful profiling, and the rotor as a whole requires special measures to ensure dynamic balance during operation. Otherwise, due to large pulsations and vibrations, destruction of pipelines and fires at joints occur due to the mutual movement of parts, friction and hardening.

To prevent fire due to breakdowns of structural elements (screw, impeller and guide vanes) under conditions of dynamic loading with subsequent fire due to rubbing of debris, means were used such as increasing structural perfection and strength due to geometry, materials and cleanliness of mining, and also the introduction of new technologies: isostatic pressing of cast billets, the use of granular technology and other types.

The oxidizer booster pump consists of a high-pressure screw and a two-stage gas turbine, which is driven by oxidizing gas taken after the main turbine with its subsequent bypass to the inlet of the main pump.

The fuel booster pump consists of a high-pressure auger and a single-stage hydraulic turbine operating on kerosene taken after the main pump. Structurally, the fuel booster pump is similar to the oxidizer booster pump with the following differences:

· a single-stage hydraulic turbine operates on fuel taken from the outlet of the fuel pump of the main HPU;

· high pressure fuel is removed to relieve the auger from axial actions from the inlet manifold of the BNAG hydraulic turbine.

Table 1: TTX TNA

Parameter	Meaning
	Oxidizer
Pump outlet pressure
Component flow through the pump
Pump efficiency
Shaft power
Shaft rotation speed
Turbine power
Turbine inlet pressure
Number of steps
Turbine pressure reduction ratio
Turbine inlet temperature
Turbine efficiency

Chapter 1. Technological part

1.1 Operating conditions of the TNA turbine blade

The TPU turbine blade (sheet No. 1) is one of the most loaded parts of the turbopump unit of a liquid propellant rocket engine. During work, the blade is affected by:

Large centrifugal forces from rotation (about 14,000 rpm).

Hot oxidizing gas heated in the combustion chamber to a high temperature of about 600°C and containing an excess of oxidizing elements and impurities leading to oxidation and gas corrosion of the surface.

High bending moments from gas forces.

1.2 Selection of material and workpiece

The casting nickel alloy TsNK-7P was chosen as the blade material, which has a higher (approximately 1.3 times) long-term strength limit, which makes it possible to increase the service life of the blades to 100,000 hours and to cast the blade feather without allowance for machining.

The disadvantage of the cast alloy is the lower endurance limit due to higher porosity compared to wrought alloys, which has always limited the use of cast alloys for long-length uncooled turbine blades.

The use of hot isostatic pressing (HIP) of castings made it possible to significantly reduce the difference in porosity and endurance limits for the feather. At the same time, for the lock, due to the larger volume of casting metal, this difference remains noticeable.

Lost wax casting is used as a casting method.

1.2.1 Chemical composition of the material

С=0.07%, Si=0.3%, Mn = 0.3%, P =0.01%, S= 0.001%, Cu = 15.5%, Co = 9.5%,

Ti = 4.4%, A1 = 4.3%, W = 6.2%, B = 0.2%, Fe = 1%, Ca = 0.01%, Mg = 0.01%, 02 = 0.002%,

Pb = 0.001%, Ni - everything else

1.2.2 Physical properties of the material (at T = 20 °C)

- elastic modulus, E = 210 GPa - shear modulus, G = 81 GPa - thermal conductivity, y = 8 W/m * K - heat capacity, Ср = 440 J/K* kg

1.2.3 Mechanical properties of the material (at T = 20 °C)

-tensile strength= 850 MPa - yield strength = 750 MPa - relative elongation - relative contraction

Impact strength

1.2.4 Heat treatment

Homogenization is used. Heating to T = 1190 0 C. The heating rate is regulated by the absence of deformation of the product. Exposure - 4 hours. Cooling at a rate of 30-45 degrees/min to T = 1050 0 C. Holding time - 2 hours. Cooling to T = 850°C at a rate of 10 - 40 degrees/min. Further, the speed is not regulated. Atmosphere: vacuum, at least 10-3 bar.

1.3 Technological process of blade manufacturing

This technological process for manufacturing the working blade of a TNA turbine differs from the previously used technical process: firstly, by using a casting subjected to hot isostatic pressing as a workpiece instead of stamping; secondly, the inclusion in the technical process of the deep-feed grinding operation, which replaced the milling and grinding operations; thirdly, the inclusion in the technical process of the operation of hydro-shot blasting hardening of the blade lock. The use of casting and HIP made it possible to eliminate mechanical processing of the blade feather, the use of deep-feed grinding reduced the labor intensity of machining the blade shank, and hydro-shot blasting hardening of the blade lock increased their endurance limit. Below is the technological process for manufacturing a blade (Table 2)

Table 2. Technological process for manufacturing a TNA turbine blade

		Treatments-	Equipment	Tool	Prisposo
operations	operations	work surface
	Control room		dispatcher
	Marking	Feather back	dispatcher	Metal marker SARURA 130
	Control	Feather back	dispatcher
	Grinding		Machine for
			deep	grinding
			grinding LSh-220	180/A-024 1-50020203
	Grinding		Machine for
			deep	grinding
			grinding LSh-220	180/A-024 1-50020203
	Grinding	Shank	Machine for
		from the outside	deep	grinding
			grinding

	Grinding		Machine for
		shank	deep grinding	grinding 180/A-013 3-1-50040 203*15°
	Grinding		Machine for
		shank	deep	grinding
			grinding LSh-220
	Control	Shank profile	Microscopy projector	UIM-21 BP-5
	Control	Shank profile	Workplace controller
	Grinding	Shank base		grinding
	Grinding		Machine for deep-feed grinding LSH-220	grinding	330/A-108 330/A-092
	Polishing	Shank profile	Polishing machine 950/582
	Marking	End of the shank from the side of the trailing edge	Drill BEBP-07A	carbide
	Control	End of the shank from the side of the trailing edge	Workplace controller
	Grinding		Machine for deep-feed grinding LSH-220	grinding	33 0/A-108 ZZO/A-093
	Polishing	Shank outline	Polishing machine 950/582	Flexible circle 1-100..12510....2020
	Grinding	Feather comb	Machine for deep-feed grinding LSH-220	grinding	ZZO/A-096 330/A-613
	Grinding	Feather shelf from the trough side	Machine for deep-feed grinding LSH-220	grinding	330/A-108 330/A-093
	Grinding	Pen shelf cutout from the trough side	Machine for depth penetration grinding LSh-220	grinding 180/A-029 1-50050203
	Grinding	Cutout on the feather shelf from the leading edge side	Machine for deep-feed grinding LSH-220	grinding	ZZO/A-097 33 0/A-108 260/A-001
	Polishing	Fillet comb and Day off	polishing 950/582 counter oller	Felt wheels with abrasive grain 25A (24A) 6...10
	Flushing
	Control		Workplace controller
	Flushing		Workplace controller
	Control room		dispatcher
	Thermal (aging)
	LUM control 1		dispatcher
	Vibration control		dispatcher		440/A-001 440/A-001
	Hydrodrobestru other hardening	Blade shank	TP1126.25. 150
	Degreasing		dispatcher
	Fatigue tests
	Determination of static moment		Installation VEM-0.5N
	Final control		Workplace controller
	I'm the picker		dispatcher
	Arrangement
	Marking	End of the shank from the entrance edge side	Drill	carbide
	Final control set		Workplace controller
	Packaging

1.4 Analysis of product manufacturability

The manufacturability of the design of a part is understood as a set of properties manifested in the possibility of optimal expenditure of labor, means, materials and time during the technical preparation of production, manufacturing, operation and repair and ensuring the manufacturability of the assembly unit that includes this part.

Calculation of manufacturability indicators:

1.4.1 Material utilization rate

where Mdet is the mass of the finished part, Mzagot is the mass of the workpiece.

1.4.2 Processing accuracy factor

Average quality of processing,

A - quality of processing;

Number of surfaces treated to this quality.

1.4.3 Application rate of standard technological processes

Number of typical technological operations;

Number of all technological operations;

In the technological process of producing a working blade, two standard technological operations are used - creep-feed grinding and polishing.

As can be seen from the manufacturability indicators, the turbine blade is a high-tech part due to the use of free-flow casting, and, consequently, the exclusion of mechanical processing of the blade from the technological process and an increase in the material utilization rate. Manufacturability is also enhanced by the use of the creep-feed grinding process, which replaced the milling and grinding operations of the blade shank.

1.5 Creep-feed grinding of parts made of heat-resistant alloys

This section takes a broad look at the creep-feed grinding process for machining parts made of heat-resistant alloys, such as a turbine blade. The introduction of this type of processing made it possible to increase the productivity of the blade production process. Deep grinding is the main operation in this process. The section discusses the history of the introduction of creep feed grinding, the theory of the process, various processing methods, types of equipment for creep feed grinding, and the grinding head.

The history of the development of the process of introducing creep-feed grinding began in the early 70s, when the rapid increase in production volumes of high-life aircraft engines forced global manufacturers in the aircraft engine industry to look for ways to solve the problem of increasing the productivity and quality of processing of particularly critical, highly loaded turbine parts, where the issues of machinability and service life were particularly pressing spicy.

An effective solution to these problems was not provided by the use of traditional methods of machining, since the acceleration of processing modes in the manufacture of parts from heat-resistant alloys is limited by the low durability of the cutting tool and the deterioration of the quality of the surface layer of the parts.

The idea of efficient material removal with abrasive wheels has always attracted the attention of specialists, since it is known that abrasive materials are superior in hardness to all known steels and alloys. There were also individual examples of solving this problem. Such examples include vulcanite cutting, productive schemes for grinding flat surfaces with a large cutting depth (up to 5 mm or more) on the side surface of a wheel with a transverse cyclic feed of up to several millimeters per stroke.

However, it has always been believed that high-performance abrasive processing processes are incompatible with ensuring high precision and quality of the surface layer of critical parts, since there is a high probability of loss of dimensional stability and the occurrence of burns. One of the ways to increase the efficiency of mechanical processing was the introduction of deep-feed grinding into production. It required solving a set of issues in order to increase the technological reliability of the process, including the development and selection of technological processing schemes; equipment; cutting and dressing tools; recipes, methods of supplying and cleaning coolant, dressing and grinding modes; theoretical and experimental confirmation of the guarantee of achieving the required accuracy and quality of the ground surface.

The peculiarity of the introduction of deep-feed grinding was that it was practically used in production and showed excellent results. Thus, in the manufacture of turbine blades, productivity increased 4 times, accuracy increased 2 times, surface roughness decreased 2 times, and the performance of the locking connection increased significantly. During experimental processing of grinding conditions and modes, all controlled indicators of the quality of the processed surface were carefully studied: roughness, depth and degree of hardening, residual stresses, microstructure, and the possibility of grinding cracks appearing. All grinding performance was better or similar to the previously used milling method. There was no difference in the level of defect occurrence in terms of the possible appearance of a discontinuity in the surface layer, revealed by the glow of the phosphor and associated with the emergence of pores and delaminations of the material along the grain boundaries formed during casting to the surface. However, after some time, this defect began to be classified as grinding cracks.

To determine the boundaries of reliable use of the process, it was necessary to study it theoretically. In our country, this was done by specialists from Rybinsk Scientists of the Rybinsk State Aviation Technological Academy (RGATA) and the industry research institute of aircraft engine technology (NIID).

The research of this group studied many aspects of the process: thermophysical phenomena in the contact zone, micro-cutting and blunting of grains, wheel wear and dressing, conditions for the existence of optimal grinding modes, cooling and the mechanism of formation of residual stresses, conditions and reasons for the appearance of process instability - which made it possible to understand well process and consciously apply it in practice.

A special case of the use of creep-feed grinding is the creep-feed grinding of parts made of nickel-based heat-resistant alloys, such as a turbine blade. It is known from production and research practice that grinding heat-resistant alloys differs from grinding structural steels. The presence in heat-resistant alloys of a strengthening intermetallic "-phase and carbides with high microhardness (HV 2030-2060) leads to intense wear of the wheel and an increase in grinding power. This is confirmed by data on the relative power and specific grinding productivity of various materials with a wide change in strength and thermophysical properties.

If we evaluate the relative grinding power of energy

dimensionless criterion (where Pz is the tangential component of the cutting force, N; Vk is the rotation speed of the abrasive wheel, m/s; V3 is the longitudinal feed of the workpiece, m/s; is the thermal conductivity coefficient of the material being processed, W/m*K; maximum contact grinding temperature), and specific productivity q - the ratio of metal removal to wheel wear per unit time, then these indicators will differ greatly for different materials, as can be seen from Table 2

Table 3

Tool wear is a consequence of abrasion and chipping of grain particles under the influence of mechanical and temperature factors. Deterioration of processing conditions causes an increase in the grinding contact temperature and increases the likelihood of surface defects appearing on the part. The occurrence of surface defects is observed to a greater extent when grinding materials that have low thermal conductivity and accumulate heat in a thin surface layer.

With multi-pass cyclic heating during conventional pendulum grinding, irreversible shaping of the grain structure of the material being processed occurs, leading to a redistribution of microstresses, which in magnitude can exceed the critical values characteristic of low-cycle fatigue. As a result, surface defects appear in the form of grinding cracks. The absence of multiple heating and cooling cycles is one of the advantages of creep feed grinding.

Thus, during deep grinding, by changing the kinetics of the thermal cycle, conditions can be created that eliminate the occurrence of thermoplastic deformations of the surface layer and weaken the intensity of phase, microstructural and diffusion processes. This is achieved by selecting the composition

and methods of coolant supply, assignment of optimal characteristics and wheel dressing cycles and cutting modes.

Conducted studies of the temperature field of the workpiece during deep-feed grinding made it possible to establish that with the actual cooling intensity created, the amount of heat that goes into the processed surface, depending on the processing conditions, is 32...83% of the total heat released. Moreover, the greater the angle of inclination (the greater grinding depth) and the lower the workpiece speed, the greater the amount of heat goes into the metal layers removed from the workpiece and the closer the maximum temperature values on its surface shift to point A (Fig. 1.1). (Qm is the ratio of the temperature at an arbitrary point of the contact arc M to the temperature at point A).

Fig. 1.1 Grinding scheme (a) and the dependence of the relative temperature along the length of contact of the wheel with the workpiece (b) during creep feed grinding: 1) Pe=1; 2)Re=0.6; 3)Re=0.4; 4) Re=0.1; 5) Re=0.02

To ensure that as much heat as possible is removed into the metal layers being removed, the kinematic parameters of the process must satisfy the following condition:

Pe is the Peclet criterion, characterizing the rate of metal removal in relation to the rate of temperature propagation into the workpiece;

Vз -- longitudinal speed of movement of the workpiece, m/s;

D -- circle diameter, m;

t -- grinding depth, m;

a is the thermal diffusivity coefficient of the processed material, m2/s.

Intense heat exchange in the grinding zone is ensured by an abundant supply of coolant under pressure. The minimum value of the heat transfer coefficient a0=(3.5...5)*103 W/(m C) serves as a measure of the cooling efficiency and temperature reduction in the area of contact between the wheel and the workpiece. Calculations have shown that if such heat transfer intensity is ensured, the temperature at point A under kinematic limitation (1) will be 300...500 C0, which guarantees the absence of defects on the treated surface in the form of burns and cracks.

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The speed of the workpiece plays a big role in the temperature of the grinding surface. With traditional types of grinding at t<0,1 мм и скорости детали Vз>10 m/min, an increase in Vz leads to a slight decrease in the grinding temperature. This is explained by a decrease in contact time with the treated surface. The intensity of heat accumulation in the surface layer decreases, and the temperature decreases. This is also facilitated by the fact that at small depths (up to 0.04 mm), an increase in Vz does not lead to an increase in the thickness of the cut layer, which becomes equal to the cutting depth, which also affects the intensity of heat generation. At greater depths, this feature is no longer observed, and the temperature increases constantly, as the thickness of the layer cut off by one grain continuously increases. These modes are the most dangerous from the point of view of burn formation (Fig. 1.2).

To limit the grinding temperature, it is necessary to sharply reduce the speed Vz, which is a prerequisite for the transition to deep-feed grinding.

During deep-feed grinding, the temperature also increases with increasing UZ. However, with an increase in the grinding depth with a simultaneous decrease in Us, the grinding temperature decreases, and the increase in depth exceeds the rate of decrease in the workpiece speed due to an increase in the amount of heat lost to the chips, which increases the productivity of the process. In addition, the thickness of the layer cut by the abrasive grain decreases, the number of cutting grains along the length of the contact of the wheel with the machined surface increases, and, as a consequence of this, the level of thermodynamic loads perceived by the grain-binder system involved in cutting decreases. As follows from the studies, these effects are observed at the ratio of the speed of the wheel and the workpiece.

Thus, defect-free deep-feed grinding is ensured under grinding conditions and coolant supply techniques that satisfy the following conditions:

Based on the studies carried out, it was concluded that since during creep-feed grinding the absolute temperature of the treated surface is low and it is more uniformly heated to these moderate temperatures, conditions for the occurrence of thermoplastic deformations and, consequently, conditions for inducing residual tensile stresses are not created in the surface layers . Thus, residual stresses are mainly formed under the action of cutting forces of abrasive grains and are compressive. This convincingly explained the numerous residual stress distribution curves obtained experimentally during the development period, some of which are shown in Fig. 1.3.

Fig. 1.3 Distribution of residual stresses in the surface layer after various processing methods: a) pendulum grinding (25A40PSM27K5 wheel, KhN62 MVKYu-VD alloy, Vk=35 m/s, Vз=0.4 m/s, t =0.05 mm); b) milling (1) ZhS6K, 2) KhN77TYUR); c) deep-feed grinding (1) ZhS6K, 2 - KhN77TYUR, wheel 24ПВМ212К5П40-20, Vk=30 m/s, V3=0.001 m/s, t=1.5 mm)

A characteristic feature of the formation of residual stresses during creep feed grinding is the identity of their distribution, regardless of some fluctuations in grinding conditions and grades of materials being processed. The distribution of compressive stresses occurs in a thinner layer near the surface of the part than during milling, which indicates a smaller penetration depth of plastic deformations.

This is confirmed by the results of microhardness measurements given in Table 4

Table 4

It follows from the table that the depth and degree of hardening during grinding is significantly less than during milling, which has a positive effect on the performance characteristics of parts operating at high temperatures.

The noted advantages of deep-feed grinding can be reliably realized when certain technological conditions for effective processing are created. Technological requirements for the process are determined by the operational characteristics of the part and the cost of its manufacture. These factors determine grinding modes, characteristics of cutting and dressing tools, method of supply and type of coolant, as well as other technological parameters.

For this purpose, technological recommendations have been developed for creep-feed grinding of high-precision gas turbine engine parts blanks from difficult-to-cut materials. They include, in addition to the general principles for assigning grinding modes indicated above, rules for selecting the characteristics of abrasive wheels and their operating conditions; editing and selection of a dressing tool; method of supply and composition of coolant; requirements for machines taking into account the specifics of creep feed grinding.

The characteristics of the cutting tool (type of abrasive material, grain size, hardness, structure, bond) are determined by the operating conditions of the abrasive grains and the requirements for processing productivity and the quality of the ground surface.

The most important indicator of the operating conditions of the grain is the maximum depth of its penetration into the material being processed, which is determined by the depth of penetration of the abrasive wheel. The greatest depth of penetration a is determined by the expression:

c -- coefficient;

Vз and Vk -- speeds of workpiece movement and wheel rotation, m/s;

t -- grinding depth, m;

D -- circle diameter, m.

Analysis of the formula shows that, other things being equal, switching to the creep-feed grinding mode while maintaining productivity reduces the thickness of the cut layer by one grain by 10...12 times, therefore the load on the grain during micro-cutting is significantly reduced, and the volume of cut chips increases. This makes it possible to use abrasive wheels of the lowest hardness VM1, VM2 and makes it necessary to increase their porosity.

Generalization of the results of studies of the strength of the grain-bond system under conditions of dynamic and thermal shock, which characterize the operation of grain during each cutting cycle under creep-feed grinding conditions, allowed us to draw the following conclusions:

for wheels with hardness VM1, VM2, Ml, the strength of the grain-bond system under dynamic impact is determined by the strength of the ligament;

the probability of destruction of the grain-binder system during thermal shock is determined by the probability of grain destruction, which, in turn, is less than the probability of grain destruction during dynamic shock;

The durability of the grain-binder system is determined by its durability under dynamic load conditions, with the weakest link in the system being the ligament.

Determining the durability of the grain-binder system and studying the condition of the cutting surface of the wheel made it possible to obtain calculation formulas and methods for engineering calculation of the dimensional stability and wear of the wheel. Without going into details of their definition, it can be noted that the durability and wear of the wheel depend on the strength of the material being processed, the size of the grinding wheel, the ratio of the speeds of the workpiece and the wheel, the ratio of the grinding depth to the radius of the wheel, the grain size and thermal diffusivity of the wheel, the density of grains in the working layer of the wheel , as well as indicators of the homogeneity of the abrasive material of the wheel and the intensity of its accumulation of fatigue damage.

When deep-feed grinding of steels and nickel-based heat-resistant alloys, it is necessary to use white electrocorundum 24A, 25A. The use of monocorundum 44A does not give the expected effect, since with an increase in the cost of an abrasive tool, its cutting properties are not fully used, since to ensure the self-sharpening mode of the wheel, the destruction of the bond occurs faster than the dulling of the grains.

The grain size of the wheel is determined by the requirements for processing accuracy and conditions for defect-free grinding. With a decrease in grain size, micro-cutting conditions improve, the cutting forces of a single grain decrease, and the durability of the grain-binder system increases. On the other hand, the number of simultaneously working grains increases, due to which the average cutting temperature increases, and the likelihood of burns increases, that is, the durability of the wheel decreases.

A similar picture is observed with increasing wheel hardness. On the one hand, an increase in hardness causes an increase in the strength of the grain-binder system and a decrease in the dimensional wear of the wheel. At the same time, this contributes to less self-sharpening of the wheel, that is, a decrease in its durability due to the appearance of a defect on the machined surface of the part.

Thus, when assigning the grain size and hardness of a tool, it is based on its dimensional and defect-free durability. In this case, the period of durability of the circle, limited by the moment of the appearance of the burn, must be no less than the period of its dimensional stability. These conditions for creep-feed grinding of workpieces made of heat-resistant alloys with small tolerances are best met by wheels with a grain size of 8...12 and a hardness of VM1, VM2, Ml.

The structure of the wheel is determined by the content of grain, binder and pores. It should be such that the chips removed in one cutting cycle can be placed in the pores of the wheel without clogging it. In addition, it must be ensured that chips are well washed out of the pores and that some of the liquid is transferred by the pores to the contact zone between the wheel and the workpiece. Only open-structure wheels have these properties, so the circle for creep-feed grinding must have a 9...12 structure.

The high porosity of the wheels is achieved by using various pore-forming substances that are burned out or melted during the manufacturing process of the wheels. In accordance with the technology developed by VNIIMASH, perlite (P), synthetic polystyrene (PSS), petroleum coke (NK), etc. are used as pore-forming fillers. Wheels with hardness VM1, VM2, Ml provide 45...50% pore content by volume of the wheel , which promotes good liquid transfer, placement and washing out of chips.

The conditions of creep-feed grinding require the wheel to have high heat resistance, rigidity, chemical resistance and water resistance. All these properties are imparted to the circle only by ceramic bonds. The most commonly used binders are KZ and K5, but along with them, boron-containing, fire-resistant, chemical and water-resistant binders alloyed with oxides of lithium, barium, copper, etc. can be used. For example, the K11 binder is characterized by a stronger bond with the grain than the KZ and K5 binders. In this case, the durability of the grain-binder system increases, which reduces wheel wear.

The main developer and supplier of highly porous abrasive wheels is VNIIMASH and JSC Ilyich Abrasive Plant (St. Petersburg). The research and production company "Exy" (Kurgan) also developed and mastered, using environmentally friendly technology, highly porous wheels using a modified K13 ceramic binder and special fillers. Tests of wheels 24А12НВМ112К13 and 24А12НВМ212К13 from this company have shown that they are not inferior to serial ones in all respects, and in some respects they are superior to them. These wheels can be used for all types of creep feed grinding.

Deep grinding in the modern sense became possible thanks to the development of a special technique for dressing abrasive wheels and the creation of a diamond dressing tool. Diamond dressing rollers are widely used. Of the basic straightening schemes using the radial and tangential cutting method, the most common is straightening by radial cutting with parallel axes of the roller and wheel. The profile of the diamond rollers in this case is the same as that of the part.

Dressing (Fig. 1.4, a) is carried out by grinding the wheel with a diamond roller with parallel rotation and a speed ratio of the roller and wheel equal to 0.6...0.8. The dressing intensity tп is estimated in microns per wheel revolution and is taken for rough dressing tп -0.8...1.0 µm/rev, and for finishing tп =0.3...0.6 µm/rev.

Editing is carried out until the specified allowance is removed. The value of t depends on the hardness and grain size of the wheel. For wheels with hardness VM1, VM2, Ml 9... 12 structures and

with grain size 10, 25.40, the optimal t value is respectively 0.05...0.08, 0.08...0.12, 0.25...0.3 mm. Smaller values correspond to harder circles (Ml), and larger values correspond to soft circles (BM1). When editing the second circle, the direction of rotation of the roller is reversed.

When dressing with tangential roller penetration (Fig. 1.4, b), the abrasive wheel is immediately fed to the value t and passes under the dressing device at speed Vc. The straightening roller rotates in one direction only, and one of the circles is reversed to ensure parallel straightening. The intensity of editing is determined by the formula:

where all designations are taken from Fig. 1.4, b and must have the same dimension.

The speed of movement of the table Vc, from this formula is determined by the given intensity of editing.

Tangential dressing provides a smoother penetration of the diamond roller and is preferable for single-circle machining.

From a quality point of view, a number of surfaces can only be processed with continuous dressing, in which the wheel is profiled throughout the entire grinding process, that is, the wheel and roller are in constant contact during the entire processing cycle (Fig. 1.5)

Compensation for wheel wear is also carried out continuously, therefore, if the diamond roller has an infeed feed Spp, then it is compensated by the feed of the entire grinding headstock to the amount of infeed and dressing, that is, Sвp + Spp.

Thanks to continuous dressing, grinding is carried out while the condition of the cutting surface of the wheel remains unchanged. Despite the fact that the consumption of an abrasive wheel increases by 1.5...2 times compared to discrete dressing, productivity increases by 5...7 times compared to conventional creep-feed grinding, and temperatures and cutting forces are reduced.

To achieve the required precision and quality of processing, both the choice of cutting fluid and its effective use are important. The choice of coolant determines the nature of temperature-strain phenomena in the processing zone, the intensity of adhesion and diffusion processes in the contact zone of the wheel with the workpiece.

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The most widely used solution for deep-feed grinding is a 1.5..2% aqueous solution of Aquol-2 emulsol. It contains extreme pressure chlorine and sulfur additives, a synthetic mixture of which reduces the intensity of adhesion and diffusion phenomena, especially when processing difficult-to-cut materials. A large percentage of water ensures high heat removal efficiency.

A promising synthetic cutting fluid is a 2...3% solution of Akvol-10M concentrate, which contains anionic and nonionic emulsifiers and fat additives. The use of this coolant reduces roughness by 15...20% and cutting forces by 10% compared to coolant based on Aquol-2.

Effective use of coolant is ensured by its supply and cleaning system. Coolant is supplied to the processing zone under pressure of 0.5...0.6 MPa with a flow rate of 80...200 l per minute per circle. The position of the cooling and additional cleaning nozzle relative to the workpiece being processed is automatically maintained as the wheel wears out. The coolant tank holds at least 1500...3000 liters and is equipped with a refrigeration device to stabilize the temperature at 20..30 "C. The cleaning device reliably retains any particles larger than 5.. 15 microns.

In some cases, the supply of coolant is intensified due to its additional supply to the ends of the circle with the application of ultrasonic vibrations. At the same time, it enters the pores of the wheel and, under the action of centrifugal forces, penetrates to the periphery, cleaning the cutting surface and additionally cooling the contact area between the wheel and the workpiece.

Creep-feed grinding has features determined by the kinematics and thermodynamics of the process, which impose specific requirements on the design of machines for creep-feed grinding. Experience in operating foreign machines, upgrading a number of domestic machines to deep-feed grinding conditions and creating our own equipment allowed Rybinsk Motors OJSC, together with NIID (Moscow), to develop technical specifications for the development of a range of domestic machines that meet the needs of the domestic aircraft engine industry.

The first to be modernized were surface grinding machines models ZB722 and ZD722 produced by the Lipetsk Machine Tool Plant. They have successfully introduced deep-feed grinding operations on the contact pads of turbine blades using a progressive processing scheme with double circles (Fig. 1.6) from the “back” and “trough” sides simultaneously.

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In conditions of limited production capacity, these machines were at one time used to process the fir-tree locks of turbine blades of gas pumping units. Outdated machines from the Matrix company (England) were also modernized for deep penetration grinding of Christmas tree locks. They introduced continuous dressing of wheels with diamond rollers with automatic size compensation, increased the power of the main drives, and re-equipped the coolant supply system.

The experience of modernizing machine tools has made it possible to further explore a number of technical solutions and lay down more reasonable requirements for them in newly developed machines.

When creating industrial models of machines for creep feed grinding at the Lipetsk Machine Tool Plant, most of the requirements were met.

The first to be created was a single-spindle machine model LSh-220 (Fig. 1.7), which is a semi-automatic machine with a rectangular table, a horizontal spindle and a four-coordinate CNC device. Machine layout in combination with design

spindle on rolling bearings ensures high rigidity of the grinding headstock. The use of fluoroplastic tape in the guides of the table and slide, as well as rolling screw pairs in the mechanisms of vertical and transverse movement of the grinding headstock feeds and table movement, made it possible to achieve smooth working movements and high precision in the manufacture of parts. The machine is widely used in factories in the industry. This machine is used in the technological process of producing TNA turbine blades.

The disadvantage of the machine was the not entirely successful design solution of the dressing device and the organization of the working area, which limited the automation of the processing cycle.

The LSh-233 machine is a semi-automatic CNC machine for double-sided creep feed grinding. It is designed for simultaneous grinding of symmetrical or asymmetrical surfaces of workpieces of various parts. The machine has continuous editing of wheels directly during processing, which is used on roughing passes. Before the finishing stroke, both circles

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Fig. 1.7 Machine LSh-220:

1 - bed; 2 - table; 3 - column; 4 - grinding head; 5 - coolant supply and cleaning system; 6 - the control panel is calibrated with one roller, which guarantees the symmetry of the profiles and high processing accuracy.

The LSh-233 machine meets the basic requirements of high-performance creep feed grinding.

Some design disadvantage of these machines is the weight imbalance of the cantilever-mounted electric motors that drive the grinding wheels.

A significant step in the further improvement of single-spindle surface grinding machines is the creation of a machine model LSh-236.

The machine significantly surpasses its predecessors in technological capabilities. It has increased rigidity, high idle speed, and a larger processing area.

The presence of a round working clock table allows for pre-installation of parts during the working cycle, which increases productivity and makes it possible to fully automate the processing cycle.

To expand the scope of application of profile grinding methods with continuous dressing of wheels when processing the surfaces of turbine nozzle blades, the LSh-278 rotary grinding machine is designed.

The machine can operate in a wide range of modes, including deep-feed grinding, and has an additional high-speed spindle for forming grooves and a tool holder for correcting them with a cutter in turning mode.

1.6 Diamond rollers for dressing

Diamond rollers are a specialized tool for dressing grinding wheels. They are used in all creep-feed grinding operations in the turbine blade manufacturing process. On sheet No. 4 of the graphic part there are drawings of rollers for operations 25, 50 and 70. These rollers are manufactured by the German company "Wendt". The difference between the diamond rollers of this company and their domestic counterparts is that the durability ranges from 50,000 to 180,000 conditional edits, while this figure for domestic rollers is 10,000-40,000 edits.

Transcript

1 MINISTRY OF EDUCATION AND SCIENCE OF THE RUSSIAN FEDERATION FEDERAL STATE BUDGETARY EDUCATIONAL INSTITUTION OF HIGHER PROFESSIONAL EDUCATION “SAMARA STATE AEROSPACE UNIVERSITY named after Academician S.P. QUEEN (NATIONAL RESEARCH UNIVERSITY)" F. I. DEMIN, N. D. PRONICHEV, I. L. SHITAREV TECHNOLOGY FOR MANUFACTURING MAIN PARTS OF GAS TURBINE ENGINES Approved by the editorial and publishing council of the federal state budgetary educational institution of higher professional education "Samara State Aerospace University named after academician S.P. Korolev (National Research University)" as a textbook for students enrolled in the educational program of higher professional education in the field of training bachelors and masters "Aircraft and Rocket Engineering" and the field of training graduates "Aircraft Engines". Under the general editorship of Professor, Doctor of Technical Sciences F. I. Demin Second edition SAMARA Publishing House SSAU 2012

2 UDC (0.75.8) BBK D 30 Reviewers: Dr. Tech. sciences, prof. V.N. Trusov, Doctor of Engineering. sciences, prof. V.R. Kargin D30 Demin F.I. Technology for manufacturing the main parts of gas turbine engines [Electronic resource]: [textbook] / F. I. Demin, N. D. Pronichev, I. L. Shitarev; under. total ed. prof. F. I. Demina. 2nd ed. Samara: SSAU Publishing House, el. wholesale disk (CD-ROM). ISBN The design features of modern gas turbine engines, technical requirements, materials used, methods of constructing technological processes, equipment and accessories used are considered. An analysis of the accuracy of the main quality indicators of the initial blanks, parts and used production means is presented. For students of higher educational institutions studying for bachelor's and master's degrees in aviation and rocket engineering, as well as for certified specialists in aircraft engines. UDC (0.75.8) BBK ISBN Samara State Aerospace University,

3 CONTENTS Preface...5 Introduction...6 Chapter 1. Features of modern gas turbine engines as production objects Basic elements and parameters of gas turbine engines Features and ways to improve gas turbine engines Manufacturability of gas turbine engines and its elements Directions for improving technological processes for the production of parts and assembly units...22 Chapter 2. Ensuring product quality indicators during manufacturing Methods for achieving the specified accuracy of quality indicators for parts and assembly units Technological conditions necessary when using the method of automatically obtaining workpiece parameters on customized equipment Structural and logical diagram for ensuring product quality indicators Formation of a fundamental plan for the technological process of manufacturing parts... 38 Chapter 3. Manufacturing of blades Design, technical requirements and materials Blade locks Blade feather Bandage flanges Blade material Technology of manufacturing blades of the first stage of turbines Technological analysis of the drawing. Details Route technology for the manufacture of turbine blades Obtaining an initial multicrystalline blank Analysis of the quality indicators of the initial blade blank Mechanical processing of blanks Creation heat-resistant coating on the working surface of the blade blade Technology for manufacturing blades of the first stage of the compressor Technological analysis of the part drawing, purpose, working conditions and materials Route technology for manufacturing blades Mechanical processing of workpieces Analysis of the quality indicators of the workpiece after completing the first part of the technological process Chapter 4. Manufacturing of disks Design, technical requirements and materials Technology for manufacturing disks of the first stage of a turbine Route technology for manufacturing disks Obtaining the initial blank of a disk Mechanical processing of disks

4 Chapter 5. Manufacturing of shafts Design, technical requirements and materials Technology of manufacturing shafts Route technology of manufacturing shafts Obtaining an initial blank for a low-pressure rotor shaft Mechanical processing of a low-pressure rotor shaft Features of manufacturing shafts from low-carbon alloy steels Chapter 6. Manufacturing of body parts Design, technical requirements and materials Technology for manufacturing body parts Obtaining initial blanks by casting Obtaining initial blanks for the inlet guide vane (IGU) body Route technology for manufacturing the IGU body Mechanical processing of the IGU body Chapter 7. Manufacturing of gear wheels of a gas turbine engine Design, technical requirements and materials Technology for manufacturing gear wheels General principles for constructing technological processes Design of a technological process Analysis of the quality indicators of a gear Manufacturing of cylindrical wheels with internal teeth Features of processing the base surfaces of gears after heat treatment Chapter 8. Composite materials Types, properties and features of producing composite materials Polymer composite materials Metal reinforced composite materials Ceramic and carbon composite materials Design technological process for manufacturing blades from polymer composite materials Requirements for the design of blades made of polymer composite materials Design features of technological equipment Technological process for manufacturing blades from PCM References Appendices

5 PREFACE The training course “Technology of Aircraft Parts” consists of six sections: 1) basics of technological process design; 2) basics of device design; 3) surface treatment methods; 4) production of engine parts; 5) engine assembly; 6) automation of technological processes in aircraft engine manufacturing. The proposed textbook covers the technology of manufacturing the main parts of engines of modern aircraft. Modern technological processes for the main parts of gas turbine engines are presented; manufacturing features are considered and a qualitative analysis of production is given. At the same time, questions already known to students from passed related disciplines are omitted and attention is focused on the manufacture of parts for new aircraft equipment. The material is divided into eight chapters, each of which discusses details that are similar in technological characteristics. In this case, the following order of presentation has been adopted: 1) design of parts, technical requirements, technological features and materials used; 2) construction of the technological process for manufacturing parts, justification of the stages and sequence of processing; 3) selection and justification of the initial workpiece; 4) performing basic operations of the technological process and analyzing quality indicators; 5) comprehensive analysis of the technological process; 6) control of the main elements of parts. The authors will gratefully accept all comments and wishes from readers, who are asked to be sent to the following address: Samara, Moskovskoe shosse, 34, SSAU, Department of Aircraft Engine Production. 5

6 INTRODUCTION Production of products in mechanical engineering has several stages: proposal, ideas and product diagrams; assessment of its need in the market and competitiveness; development of a preliminary design; preliminary calculations and checks; execution of product design drawings; comprehensive analysis of structures, calculation of output quality indicators; performance check; assessment of the reliability and strength of the product and its individual elements; checking the manufacturability of the design, the ease of use of the product, as well as other necessary work related to the design of engineering products. In the process of creating a structure, designers use existing experience, existing means of production, methods of manufacturing and control of individual parts and assembly units. When designing products, the prospects for improving production methods and means, and the emergence of new materials and technologies are taken into account. The development of new gas turbine engines (GTE) and their introduction into production are closely related to the features of these highly loaded, structurally and technologically complex products. The use of light aluminum and magnesium alloys, high-strength alloy steels and heat-resistant chromium-nickel alloys, the use of titanium alloys, composite and other materials requires a careful assessment of the economic indicators of production. The use of modern methods for processing the surfaces of workpieces, methods for obtaining initial workpieces, and the features of manufacturing parts in small production runs determine the essential nature of aircraft engine building. Operation of gas turbine engines at critical rotation speeds of flexible rotors, with high temperature loading of individual structural elements and significant temperature gradients in different zones of the product places high demands on the quality of parts and assembly units. 6

7 CHAPTER 1. FEATURES OF MODERN GTE AS PRODUCTION OBJECTS 1.1 MAIN ELEMENTS AND PARAMETERS OF GTE Gas turbine engines are widely used in aviation. They can be divided into the following groups: turbojet (TRD), turboprop (TVD) and intermediate turbojet bypass engines (DTRD). Currently, turbojet engines have completely established elements (see Fig. 1.1). 1) input device; 2) compressor; 3) combustion chamber; 4) power housing connecting the turbine and compressor; 5) turbine; 6) exhaust system; 7) housing of unit drives; 8) fuel, oil and other systems and units. In turbojet engines and high-pressure engines, exclusively axial compressors are used due to the fact that they allow a higher degree of pressure increase, have high efficiency, low weight and small transverse overall dimensions. The compressor, combustion chamber, turbine and jet nozzle in the gas turbine engine are positioned so as to obtain an intermediate path in which low hydraulic losses occur. Gas turbines for high-thrust engines are used exclusively of the axial type. To boost turbojet engines, afterburners located behind the turbine are widely used. Diagram of a turbojet engine with an afterburner, shown in Fig. 1.1, is the most typical for modern diesel engines. The main parameters characterizing the quality technical indicators and the degree of perfection of the gas turbine engine include: thrust; engine specific gravity; dimensions; specific fuel consumption, resource, etc. 7

8 Fig Diagram of a turbojet bypass engine with an afterburner 8

9 Comparative assessment of engines with different thrust is determined by their specific mass, which is understood as the ratio of the engine mass to its rated thrust R (given). This indicator is constantly decreasing in the process of development of engine design and production technology. Thus, for the first turbojet engines with an axial compressor this figure was 1.1, and for modern designs it was 0.05. Low specific gravity is a critical requirement for aircraft engines. The overall dimensions of the engine are characterized by the midsection area F and length L. The midsection area F is of greatest importance, since it determines the drag of the aircraft. During the development of gas turbine engines, the reciprocal of the specific frontal area (1/ f frontal = R/F, where f frontal cross-sectional area of the engine) increased significantly: at the beginning of the development of gas turbine engines it was dan/m 2 for turbojet engines, currently it has been increased up to dan/m2 or more. Specific fuel consumption C e /R, determined for a turbojet engine by the ratio of fuel consumption C e (kg) to thrust R (given for 1 hour), is constantly decreasing. So, for bench tests it was 1.3 1.5 kg/(dahn h) on the first gas turbine engines; currently for turbojet engines it is 0.7 kg/(dahn h) or less, and for DTRE it is less than 0.5 kg /(given h). This indicator is important for modern gas turbine engines. Specific fuel consumption depends on the design of the gas turbine engine and (to a large extent) on the quality of parts and assembly units. An increase in the relative radial clearance (the ratio of the radial clearance to the length of the blade) by 1% leads to a decrease in compressor efficiency by up to 3%, which causes an increase in fuel consumption by up to 10%. This is explained by the fact that with large gaps, the flow of air from the cavity with higher pressure into the cavity with lower pressure increases and the compressor pressure decreases. At the same time, increased deflections of the rotor and stator due to unbalanced forces and moments, both in magnitude and direction, as well as temperature deformations necessitate an increase in radial clearances, which leads to a deterioration in the efficiency of the compressor and turbine and a decrease in the range of stability of the compressor. Thus, an increase in radial clearance by 1% narrows the range of stability by 12–14%. Increasing the dimensions of the walls and diameters of the shafts often does not provide an advantage in terms of weight of the structural design of a gas turbine engine with a small number of supports. This condition determines the importance of choosing the number of supports in the gas turbine engine. As engine construction develops, the service life of gas turbine engines continuously increases. If at the beginning of the development of a turbojet engine its resource was hours, then at the moment it has grown significantly. It should be noted,

10 that the resource depends on the purpose of the product (civil or military options, reusable or disposable use). During the development of gas turbine engines in mass production, the engine life changed from 50 hours to 5-10 thousand hours or more; and for converted products of the NK series it is at least 50 thousand hours. Changes in the quality indicators of gas turbine engines over time depend on the design and (to a greater extent) on the technological improvement of the production processes of parts and assembly units. In addition to the listed main quality indicators of products, other quality characteristics of gas turbine engines can come to the fore, for example: ease of maintenance and repair of the engine during operation; modular engine design; stability of quality characteristics over time when operating in different climatic conditions, etc. FEATURES AND WAYS TO IMPROVE GTE Aircraft engines operate under difficult conditions when operating in different climatic zones. Requirements for product reliability are constantly growing. Engine quality indicators are increasing. The costs of manufacturing individual parts and assembly units are increasing. These conditions determine ways to improve gas turbine engines. 1. Use of lightweight, openwork, complex design of parts and assembly units of gas turbine engines (Fig. 1.1). The body parts have a thin-walled design with various recesses, reliefs, stiffeners, shaped surfaces of working contours, etc. The intermediate rings of the compressor and turbine housings have significant diameters with a small wall thickness. The working path of the compressor and turbine is performed with minimal profile deviation from the nominal position. The compressor and turbine rotor blades, as well as straightening and nozzle blades, have a complex spatial shape with small profile thickness dimensions and high-precision locking elements. The compressor and turbine rotor disks have a lightweight design (the thickness of the compressor disk web is 3-5 mm) with a reinforced hub and bandage. GTE shafts have a significant length with relatively small diameters and wall thickness. They contain many 10

11 working surfaces in the form of splined, threaded, keyed, and sometimes toothed elements. The combustion chambers have a complex spatial shape and are made of thin-sheet material, which ensures significant differences in temperature and forces during gas turbine engine operation. 2.Improving the gas turbine section of the gas turbine engine and optimizing the temperature stress of structural elements, aimed at increasing the efficiency of the turbine and compressor. Gas-dynamic improvement of the tract is one of the main ways to improve the quality indicators of gas turbine engines. Even a slight improvement leads to significant savings in energy resources. High-temperature turbines of modern and promising gas turbine engines are distinguished by increasingly intensive cooling of the first stages, relatively short lengths of their blades and high gas-dynamic loading, leading to the occurrence of supersonic speeds and large angles of rotation of the flow at the crowns. Due to the high degree of expansion, the flow part of the turbine is obtained with a significant meridian opening and a strong change in the radius parameters in the last stages. Research to improve the quality indicators of turbines and improve methods for designing a gas-dynamic path made it possible to obtain high efficiency from fourth-generation aviation gas turbine engines. For single-stage compressor turbines, the efficiency is 0. For two-stage compressor turbines and multi-stage fan turbines, the efficiency is 0.91 0.915. When testing the TVVD gas generator of the NK-93 series, it was found that the first stage of the turbine achieved an efficiency in the range of 0.91–0.92. Improvement of the gas turbine engine path has led to a change in the geometric shape of the profiles of the blades of the rotor and stator parts, for example: in turbojet engines, high-pressure engines and power plants of the NK family (86,144,321,93,14,16, etc.) profiles of an alternating curve on the trough or blades of different thicknesses are used, at which the grid entry angles were optimized; the turbojet engine uses stages with inclined and saber-shaped nozzle blades twisted back at the inlet angle; coolant was blown into the trough near the inlet edge and back pressure was created during blowing. eleven

12 3. Use of modern materials (aluminum, magnesium, titanium, chromium-nickel heat-resistant alloys, various composite materials) and heat-resistant ceramic coatings. The choice of material is determined by the heating temperature and the force applied to engine parts during operation. At temperatures below 200 C, magnesium alloys are used, at temperatures around 250 C, sheet duralumin, at temperatures up to 500 C, stainless steel (corrosion-resistant), and at temperatures above 1000 C, heat-resistant chromium-nickel alloys. Thus, the blades of the inlet guide vane of the low-pressure compressor and the blades of the low-pressure rotor are made of low-alloy heat-resistant steels Kh12N9, Kh15N5D2T and titanium alloys, and the stator and rotor blades of the high-pressure compressor are made of chromium heat-resistant alloy steels, as well as heat-resistant steels and nickel alloys. chrome base (nichrome). The introduction of aluminum (up to 3.5%) significantly increases the heat resistance, heat resistance (especially in the temperature range C) and manufacturability of the alloys. The turbine nozzle blades are made of heat-resistant high-alloy alloys. Titanium, molybdenum, niobium in small quantities, as well as tungsten are used as alloying elements. Tungsten significantly increases the heat resistance of alloys and almost does not impair heat resistance. In table 1.1 presents an approximate list of the main materials used for parts installed in various areas of the engine, and thermal processing operations. Increasing operational requirements for gas turbine engine parts has caused the emergence of new heat-resistant and heat-resistant materials. Thus, for the manufacture of cooled turbine blades with an internal cavity, the technology of lost wax casting with nickel-based alloys (ZhS6KVI, ZhS6uVI, ZhSFVI, ZhS-30, ZhS-30VI, ZhS-40, VZhL-12E, etc.) is used, which have good mechanical properties (σ in = 850 Pa/mm, relative elongation δ = 3 5%, relative contraction ψ = 4 7%) and long-term strength at a temperature of 975 C and a load of 20 N for an hour. These materials provide the technology for the manufacture of free-flow blades . 12

13 Table 1.1 Materials used for the manufacture of gas turbine engine elements Main assembly units of gas turbine engine Input guide Main elements of assembly units Materials used Heat treatment Outer shell 38ХА, 38Х2МУА З+О, ОН, ОВ ХШ Method of obtaining initial blanks and structures apparatus (VNA) VNA housing AMC , D16 OTZH, Z+ST L, Sh Compressor Outer shell 38Х2МУА, З+О, ОН ХШ, Sv, SbK low pressure 13Х3Н13М2Ф (KND) Compressor housing R ХШ, Sv, SbK 30Х13 15Х16Н2AM 30ХГСА 13Х11Н2В2МФ OTZH, Z+O N + OV Z+O OTZH, Z+O Stator blades 1Х12Н9, Х15Н5Д2Т, VT-20, VT-9 N+OV, N+O OTZH SHAFT IZSH, TOSH, VSS Rotor blades VT-9 VT-20 EP-517, EP- 718ID OTZH OTZH Z+O IZSH, OSH IZSH, VSSH Sh, VAL Discs VT-9 VT-20 OTZH OTZH Sh Sh Labyrinth 18KHNVA, 40KHNMA N+OV Sh seals 13KHN14VFRA Z+O Sh X24N25T Z+O Sh Middle support housing (KSO ) AL-4, AVT1 Z+S L 13

14 Main assembly units of gas turbine engines Main elements of assembly units Outer shell Materials used 38Х2МУА 13Х3Н13М2Ф 15Х16Н2AM Heat treatment Z+O, OH KhTO Z+O Continuation of the table. 1.1 Method of obtaining initial blanks and structures KhSh, Sv, SbK High pressure compressor (HPC) Compressor housing Stator blades 15Х16Н2АМ 30ХГСА 13Х11Н2В2МФ Х15Н5Д2Т 1Х17Н2 Х15Н5Д2Т VT-9 EP-517, EP-718ID ZhS6UVI N +OV Z+O Z+O Z + O Z+O Z+O OTZH Z+O Z+O R KhSh, Sv, SbK Sh, VSSh, IZSH, VAL Rotor blades VT-20 EP-517, EP-718ID OTZH Z+O IZSH, VSSh Sh, VAL Disks VT-9 VT-20 OTZH OTZH Sh Sh Labyrinth seals 18KhNVA, 40KhNMA 13KhN14VFRA Kh24N25T N+OV Z+O Z+O Sh Sh Sh 14

15 Main assembly units of gas turbine engine Combustion chamber (CC) Main elements of assembly units Materials used Heat treatment Continuation of table. 1.1 Method for obtaining initial blanks and structures Outer casing Kh18N9T, VZh98, VZh102 Z, Vz KhSh, Sv, SbK Flame pipe Kh77TYUR (EI-437B) KHN77TYUR-VD (EI-437B-VD) KHN77TYURU-VD (EI437BUVD) KHN78T (EI- 435) KhN80TBYu (EI-607) Z+Sb KhSh, Sv, SbK Turbine Outer shell KhN77TYURU-VD (EI437BUVD) KhN78T (EI-435) KHN80TBYu (EI-607) ZhS6U-VI Z+Sb KhSh, Sv, SbK Turbine body Stator blades KhN80TBYu (EI-607) ZhS6U-VI KhN80TBYu (EI-607) ZhS6U-VI, ZhS6FVI Z+Sb Z+Sb KhSh, Sv, SbK KhSh, Sv, SbK 15

16 Continuation of table. 1.1 Main assembly units of gas turbine engine Turbine Main elements of assembly units Rotor blades Materials used KhN77TYURU-VD (EI437BUVD) KhN78T (EI-435) KhN80TBYu (EI-607) ZhS-3, ZhS6-K, ZhS6U-VI ZhS6F-VI, ZhS-40 ZhS-30VI, ZhS-30 Heat treatment Z+Sb Method of obtaining initial blanks and structures Sh, LNK, MKO Shaft Rear support, power unit (ZO) Disks KhN77TYURU-VD (EI437BUVD) KhN80TBYu (EI-607) KhN62BMKTYU-PD Z+ Sb Shzsh Labyrinth rings VZHL-14, VZHL12U Z+Vz Sh Low pressure shaft 15Х12Н2МВDAБ-Ш Н, З+О Ш High pressure shaft 15Х12Н2МВDAБ-Ш N, З+О Ш Bearings SbK Outer shell Х18Н9Т, VZH98, VZH102 З, Вз ХШ , St, SbK 16

17 Basic assembly units of the GTD Rear support, power unit (z) exhaust device Basic elements of the assembly units The rear support housing used materials 13x11N2MF, x15N5D2T, x77TUR (EI-437B) XN77TUR-VD (EI-437B-VD) Aggregates 38xmua , Fuel, air, oil systems 17 C+O Heat treatment Continued table. 1.1 Method of obtaining initial blanks and structures KhSh, Sv, SbK Outer shell Kh18N9T Z, Vz KhSh, Sv, SbK Afterburner Kh18N9T, VZh98, VZh102 Z, Vz KhSh, Sv, SbK Jet nozzle VZh98, VZh102 Z, Vz KhSh, Sb, SbK Body parts AK4-1, AK6, AK8, Z, S L, Sh VT3, VT9 OTZH N, Ts, Z+O Sh N, Az, Z+O 40ХНМА, 40ХН2МА-Ш Н, З+О Pipelines 1Х18Н9Т, Х17Н13М3Б N, C, Z+O Pr Compensators 1Х18Н9Т Н, Ц, З+О Ш 1Х18Н9Т Н, Ц, З+О Ш Fastening elements Note. Legend: Z hardening; About vacation; OH release is low; RH holiday is high; annealing; ST aging; N normalization; Sat stabilization; Air cooling; C cementation; Az nitriding; ХШ cold stamping; L casting; Ш stamping; St welding; SbK Prefabricated structure; P rolling; SHAFT rolling; IZSh isothermal stamping; TOSH precision stamping; VSSh high-speed stamping; L casting; LNK casting with directional crystallization; MKO monocrystalline casting; Pr rental,

18 Due to the increase in temperature at the inlet to the gas turbine engine, technologies are used to create two, three-layer heat-resistant, thermal barrier coatings with flows of high-temperature pulsed plasma. An outer ceramic barrier layer (ZrO 2 Y 2 O 3, ZrO 2 MgO) µm thick is applied to a ceramic and metal sublayer (65/35) and a metal layer (Ni Cr Al Y) located on the main substrate. The thickness of the system reaches 500 microns. Thermal hardening makes it possible to create a durable ceramic coating, which helps to increase the durability of highly loaded gas turbine engine elements. 4. Application of thermal and thermochemical effects on the main parts of the gas turbine engine. In the practice of heat treatment of steels and alloys, phase transformations occur, for example: the disordered structure of a ferrocarbide mixture (ferroperlitic, pearlitic with excess carbide) in steel, when heated above critical points, transforms into a polymorphic state, and upon passing through the critical point, a fine grain of austenite is formed. Depending on alloying and heating rate, steels are grouped according to the degree of manifestation of structural heredity. The alloying of steel affects the critical heating and cooling point. Carrying out high-quality heat treatment of gas turbine engine parts made of various steels and alloys largely determines the quality of the product (see Table 1.1). The place of thermal operations in the technological process of manufacturing parts and assembly units, especially for low-rigidity gas turbine engine structures, is often decisive. In table Table 1.1 shows the main thermal and thermochemical operations for parts at various stages of the manufacturing process. 5. Ensuring high precision manufacturing of parts, assembly units and the entire product. Shown in Fig. 1.1 radial clearances Р 1, Р 2, Р 3,..., Р n between the compressor and turbine blades with housing elements; axial clearances O 1, O 2, O 3,..., O n; the gaps B 1, B 2,..., B n between the shafts, as well as the gaps L 1, L 2, L 3,..., L n in the labyrinth seals determine the thrust, fuel consumption, temperature stress of structural elements and the efficiency of individual components and the entire engine. The accuracy of the location of parts relative to each other is an important characteristic of quality indicators. The accuracy of the geometric parameters of the gas turbine engine is the key to reliable and high-quality operation of the entire product. At the same time, the accuracy of, for example, the radial clearance Р n is determined by the manufacturing accuracy 18

19 included parts: turbine blades and disk (p 1 and p 2), bearing (p 3, p 4) and stator (p 5, p 6). In this regard, the accuracy indicators of individual gas turbine engine parts are very high: working journals of shafts within IT5; shaft neck shapes up to 0.003 mm; permissible runout of the shaft journals relative to each other is no more than 0.01 0.02 mm; locks of compressor and turbine blades within IT5 and above; the location of the blade lock elements relative to each other is not more than 0.008 mm; gaps in the labyrinth seals of the compressor and turbine 0.03 0.04 mm; gaps in the wheel rims of turbine wheels of stages 1 and 2 are not more than 0.05 mm; permissible displacement of the airfoil profile of the compressor blade, turbine, nozzle and guide vane is not more than 0.08–0.15 mm; dynamic balancing of compressor and turbine rotors within 0.3 0.4 N/cm 2, etc. Dimensional calculations carried out at the design stage and during product assembly are based on the assumption of the ideal shape and relative position of the boundary surfaces of the parts. Real surfaces of parts in their topographic shape and relative position due to technological errors can differ significantly from the idealized prototypes used as the basis for dimensional calculations. As studies show, it is the contact phenomena corresponding to each pair of contacting surfaces that determine the stability of the output characteristics of the product. In Fig. Figure 1 shows the junction of the compressor rotors and the gas turbine engine (element A). The contact conditions of this interface are very important: the reliability of the product directly depends on the quality of the joint surfaces of the connection. At the junction of the turbine blades in the upper shroud, contacts between the blade elements occur, which operate under significant dynamic and temperature loads during operation. The reliability of the entire product depends on the quality of preparation of these elements. In this regard, in problems arising during dimensional analysis of a product, the joint zone is represented as a (component) link in the dimensional chain. The joint link is represented as a closing link 19

20 contact chain, in which the constituent links are contact deformations (approximations) of the butting surfaces of the mating parts. The operation of gas turbine engine joint elements can be plastic, plastic with hardening, elastoplastic and elastic in nature. At the same time, the requirements for the condition of the surfaces of butt joints increase significantly. Thus, the roughness of the butting surfaces of the blades is determined by the values of Ra 0.2 - 0.32 μm and higher, the accuracy of these surfaces is IT5 IT8 and special finishing operations are often required when assembling turbine and compressor wheels. With such ways of improving gas turbine engines, the complexity of manufacturing individual parts and assembly units has increased significantly. For example, the use of turbine blades in gas turbine engines, made of heat-resistant, difficult-to-process alloys, with a complex internal cooling cavity with very high requirements for the accuracy of the airfoil profile, the accuracy of the lock and shrouds, has dramatically complicated production. The use of large-diameter intermediate rings (1.5-2 m) with small wall thicknesses (8-10 mm) and large side flanges for fastening in gas turbine engines increases the duration of the technological process and the material consumption of the product. The use of traditional methods for obtaining ring blanks and processing methods for difficult-to-process materials complicates production tasks. This situation in the development of gas turbine engines has brought to the fore the tasks of improving methods and means of producing parts and assembly units. Strict requirements for the timing of the development of new products in production (the development period for an engine should be no more than 2-3 years) with relatively small batches of manufactured products make these tasks very difficult. The creation of competitive gas turbine engines with good economic production indicators necessitates the development of quickly adaptable and cost-effective technological processes for the manufacture of modern products. 20

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1.1 Operating conditions of the TNA turbine blade

1.2 Selection of material and workpiece

1.2.1 Chemical composition of the material

1.2.2 Physical properties of the material (at T = 20 °C)

1.2.3 Mechanical properties of the material (at T = 20 °C)

1.2.4 Heat treatment

1.3 Technological process of blade manufacturing

1.4 Analysis of product manufacturability

1.4.1 Material utilization rate

1.4.2 Processing accuracy factor

1.4.3 Application rate of standard technological processes

1.5 Creep-feed grinding of parts made of heat-resistant alloys

1.6 Diamond rollers for dressing

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