1.Overview
Blades are widely used in large-scale power equipment, such as aviation turbine engines, gas turbines, fans, compressors and other fields, and are its core components.
The blade is the "heart" of turbomachinery and is the most important part of turbomachinery. A turbine is a rotating hydrodynamic machine that directly plays the role of converting the thermal energy of steam or gas into mechanical energy. Blades generally work under high temperatures, high pressures and corrosive media. The moving blades also rotate at a very high speed. In large steam turbines, the linear velocity at the tip of the blade is as high as 600 m s, so the blade is also subjected to a great deal of centrifugal stress. The blades are not only numerous, but also complex in shape, with strict processing requirements, and the processing workload of the blades is very large, accounting for about one-quarter to one-third of the total processing volume of steam turbines, gas turbines and turbine engines. The processing quality of the blade directly affects the operation efficiency and reliability of the unit, and the quality and life of the blade are closely related to the processing mode of the blade. Therefore, the processing method of the blade has a great impact on the working quality and production economy of the turbomachinery. This is why the turbomachinery industry at home and abroad attaches great importance to the study of blade processing. With the development of science and technology, the processing methods of blades are also changing with each passing day, and advanced processing technology is being widely adopted.
The blade manufacturing process generally involves the following steps:
1.Design and model making: According to the design requirements and performance requirements, the three-dimensional design of the blade is carried out using computer-aided design (CAD) software. Then, a model of the blade is made using a CNC machine or 3D printing technology.
2.Material preparation: Select the appropriate material, such as composite materials (e.g., carbon fiber reinforced composites) or metal materials (e.g., steel, aluminum, etc.). Prepare the required materials and supporting materials.
3.Mold preparation: according to the model of the blade design, make the corresponding mold. Molds can be used for the lamination of composite materials or the die-casting of metal materials.
4.Material molding: According to the design of the blade and the mold, the material is molded. For composites, a lamination process is typically used, in which a pre-cut fabric is impregnated with resin and then layered on top of each other, and then cured by pressure and temperature. For metal materials, die-casting or other appropriate processing techniques can be used.
5.Preliminary processing: The formed blade may need to undergo preliminary processing, such as trimming the edges, sanding the surface, etc.
6.Layup and coating: Apply appropriate coatings or surface coatings to the blades as needed to provide protection, reduce friction or improve aerodynamic performance.
7.Inspection and testing: Quality inspection and performance testing of blades, including size, shape, weight, strength, vibration characteristics, etc.
8.Assembly and completion: According to the specific use requirements, the blades are installed into the corresponding equipment or system to complete the overall assembly.
2.The application of 3D scanners in the field of blade modeling
The forward design of blades needs to go through an extremely complex process, including aerodynamics, mechanics, materials science, etc., so it is more economical to quickly realize the production of blades through reverse modeling and improvement of existing products. The 3D scanner can obtain the 3D data of the existing blade through fast 3D scanning, and obtain its CAD model through the reverse engineering system, and improve the existing CAD model through a series of studies such as CAE and fluid **, combined with the design requirements of power equipment.
The ATOS Q system is a compact blue-light 3D scanner that quickly obtains high-quality 3D data of existing blades, enabling companies to quickly reverse modeling. The simple process is as follows:
3.Application of 3D scanners in the field of blade quality control
Dimensional control of the produced blades is also an important part of the blade manufacturing process. As mentioned earlier, through the blue-light 3D scanner, the overall 3D data of the blade can be quickly obtained, and the obtained 3D data can be compared with the CAD model, and the overall knowledge of whether the processed blade meets the design requirements can be obtained.
In addition, through professional blade detection software, the key control parameters of the blade, such as blade chord length, leading edge diameter, trailing edge diameter, etc., are obtained.
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