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Магистр ДонНТУ Васьковский Антон НиколаевичVaskovsky Anton Nikolaevich

Faculty: Mechanical

Speciality: Technology of machine building

Theme of master's work:

Improvement of the structural and technological support for processes of the shoulder-blades manufacturing for compressor gas-turbine engine under conditions of Snezhnyanskiy machine-building plant

Scientific adviser: professor Mihajlov Alexander Nikolaevich

Abstract on subject of the graduate work

Сontents

     Introduction
Actuality of work
Purpose and tasks of work
Scientific novelty of work
     Basic part
Shoulder-blades of compressor of gas-turbine engine
Forming of superficial layer on the operations of finishes of making of shoulder-blades
Vibroabrazivnaya treatment of shoulder-blades
     Conclusion
     Literature

Introduction

Actuality of work

      A resource and reliability of aviation engines is mainly determined as bearing strength of shoulder-blades of compressor (fig. 1), it’s the most responsible and high-loaded details, testing in the process of exploitation the considerable parts and cyclic loadings which influence on them with large frequencies. Shoulder-blades of compressor are the most mass, high-loaded and responsible detail of aviation engine.
      The feature of shoulder-blades of compressor, having thin edges of entrances and outputs and made from titanic alloys, very sensible to the concentration of tensions, is that they meet the first with a foreign body (bird, hail and other), getting in the highway of engine.
      Risks, erosive damages and other defects multiply the level of local vibrations & tensions is considerably, that reduces durability descriptions of shoulder-blades sharply. Therefore creation of combination of properties of superficial layer on the consolidating operations of finishes has large influence on the increase of bearing strength of shoulder-blades of GTE. An actual task is an estimation of influencing of the superficial deformation consolidating on shock durability of shoulder-blades at shoulder with extraneous objects.

Model of the blade of the compressor GTE (10 shots, 20 cycles)

Figure 1 - Model of the blade of the compressor GTE (10 shots, 20 cycles)

Presently at making of shoulder-blades of compressor wide application was got by the methods of plastic deformation and tooling, and also complex technologies on the operations of finishes of technological process.
Vibration treatment (VP) on the special options found wide application in the production of shoulder-blades of compressor from titanic alloys. Positive influence on efficiency of vibrations treatment renders application together with the abrasive chemically active liquids.
      Ultrasonic treatment marbles (UZU) allows to form combination of descriptions of superficial layer of shoulder-blades of compressor, having small inflexibility, high exactness of making, complicated configuration and thin edges.
      Press treatment (PDU) is characteristic sliding of marbles with the surface of feather of shoulder-blade, shutting out them. It is set that PDU is accompanied diminishing of structural heterogeneity and gives a structure, distributing of phases and remaining squeezing tensions more homogeneous character in the superficial layer of feather of shoulder-blade. Technological micro-defects of superficial layer, formed on the previous stages of technological process, accompanied the considerable increase of limit of endurance, by the decline of dispersion of longevity and does not require the subsequent polishing of thin edges the hand polishing [6].
      One of perspective methods of consolidating treatment is a method of the magnetically-abrasive polishing (MAP). The distinguishing features of MAP consist of possibility of process details with different configuration and combine finishing and consolidating operations in one process. A problem of erosion of shoulder-blades of engines of gas-turbines is confessedly. Intensity and type of erosion of shoulder-blades of compressor depend not only on the terms of particles with the surface of feather but also of combination of descriptions of superficial layer.
For the increase of wear-proof of shoulder-blades more wide application was got by the different types of complex technologies is causing of plasma coverage in combination with different consolidating methods.
      Development and applying in serial industry of engines is presently accompanied progressive designer-technological decisions, expressed in appearance of new details, application of on principle new materials of constructions, and also improvement of technologies of production, assembling and test. The progressive technological processes of tooling, based on conception of the high-speed cutting, are widely used in the methods of consolidating and heat treatment will be perfected.


contents

Purpose and tasks of work

      A purpose of work - is an increase of longevity and quality of shoulder-blades of compressor of GTE due to perfection of the structural and technological providing of processes of making of shoulder-blades of compressor of GTE.

      Basic tasks of work:
1.) To conduct the analysis of the modern state of the structural and technological providing of processes of making shoulder-blades of compressor of GTE;
2.) To explore possibilities of increase of longevity of shoulder-blades of compressor by causing of ion-plasma coverage;
3.) To execute experiments on research of properties of wear-proof ion-plasma coverage;
4.) Development of recommendations on perfection of the structural and technological providing processes of making shoulder-blades of compressor of GTE.


сontents

Scientific novelty of work

      The scientific novelty of work consists in development of recommendations on perfection of the structural and technological providing of processes of making of shoulder-blades compressor of GTE and creation of optimum structure of technological process of treatment of shoulder-blades of compressor of GTE. Also this work foresees the decision of problem of wear-proof of shoulder-blades of compressor of GTE.


сontents

Basic part

Shoulder-blades of compressor of gas-turbine engine.

      The shoulder-blades of GTE work in the conditions of high temperatures, arriving at for a turbine above 1200°С, for a compressor above 600°С. A frequent change of the thermal modes of operations of engine is the rapid heating in the moment of start and rapid cooling in case of stopping of engine - causes the cyclic change of thermal tensions, characterized as a thermal fatigue (fig. 2).

Scheme of the motion of gas streams in GTE (3 shots)

Figure 2 - Scheme of the motion of gas streams in GTE (3 shots)

      The production of shoulder-blades of GTE is occupied by the special place in air-jet motor options, that is under a number of factors main which it is been defined as:
• Difficult geometrical form of feather and the end of shoulder-blades;
• High exactness of making;
• Application of expensive materials, such, as the alloyed became titanic alloys;
• Mass character of production of shoulder-blades;
• Equipped of technological process the expensive specialized equipment;
• High labor intensiveness of making.
      For the production of shoulder-blades of GTD the followings types of tooling are characteristic for today:
• reaching;
• milling;
• rolling;
• polishing;
• Vibration levels;
• Heat treatment [11].


contents

Forming of superficial layer on the operations of finishes of making of shoulder-blades

      At making of shoulder-blades of GTE micro-unbalance, risks, appear on their surfaces, and there are structural and phases transformations in a superficial layer. In addition, there is an increase of hardness of metal and forming of remaining tensions in a superficial layer.
      Principal reasons of origin of micro-pressure at tooling is heterogeneity of plastic deformation and local heating of metal of superficial layer, and also transformations of phases.
      A degree and depth of incline of superficial layer of details is conditioned the modes of tooling and directly related to multiplying the amount of distributions, vacancies and other of defects of crystalline grate of metal.
      There is formation of remaining at tooling of details tensions it is related to uneven plastic deformation superficial layers, which flows at co-operation of power and thermal factors.


contents

Vibroabrazivnaya treatment of shoulder-blades

      A place of treatment by vibrations is in the technological process of mechanical work shoulder-blades, as a rule, finish process, executable on the finishing stage of treatment.
      The process of treatment of details considerably activates and intensify into the closed container with two bottoms, located opposite each other, if friable actively hesitates between them, collecting kinetic energy of shove from every bottom. Intensity of surroundings with the processed detail increases substantially. The lateral walls of container are executed sloping (conical), it creates the additional wringing out by them ,during his motion, that multiplies forces of dynamic influence between abrasive and walls of container into which the processed details of GTE are disposed in the fastened or free state.

Dependence of roughness on treatment by vibrating

Figure 3 – Dependence of roughness on treatment by vibrating in U-vivid container (1) and by the method of POVO (2)

      Achieving the roughness of Ra=1.5 by the above method of POVO, as follows from fig. 3, takes place approximately after 30 mines, and by ordinary treatment — 1,5 hours [1].
      Research of treatment of shoulder-blades of turbines and compressors shows advantages of this process as compared to polishing and glossing by hand.


contents

Conclusion

      A large value is in the decision of problem of providing of resource and reliability of aviation GTE, and also development, perfection and creation of new technological processes, has creations of engines of new generations, methods of treatment of details and equipment, which promote not only the productivity but also quality of making.

contents

Literature

1. Богуслаев В. А., Яценко В.К., Притченко В.Ф. Технологическое обеспечение и прогнозирование несущей способности деталей ГТД. -К.: Издательская фирма «Манускрипт», 1993. - 332 с.
2. Дриггс И. Г., Панкастер О. Е. Авиационные газовые турбины. Пер. с англ. Г.Г. Миронова. — М., Оборонгиз, 1957 — 265 с.
3. Жирицкий Г. С. Авиационные газовые турбины. —М., Оборонгиз, 1950 — 511 с. 4. Доронин Ю.В., Макаров В.Ф. Причины образования дефектов на профиле пера титановых лопаток при полировании.// Там же. – 1991. - №12. – С. 17- 19
5. Колощук Э.М., Шаботенко А.Г., Хазанович С.В. Объемная виброабразивная обработка деталей ГТД. // Авиац. прои-сть. – 1973. - №6. С7 13 -16
6. Богуслаев В.А., Яценко В.К., Жеманюк П.Д., Пухальская Г.В., Павленко Д.В., Бень В.П. Отделочно-упрочняющая обработка деталей ГТД – Запорожье, изд. ОАО «МоторСич», 2005 г. – 559 с.
7. Демин Ф. И., Проничев Н. Д., Шитарев И. Л. Технология изготовления основных деталей газотурбинных двигателей: Учеб. пособие. — М.: Машиностроение. 2002. — 328 с.; ил.
8. Сулима А.М., Шулов В.А., Ягодкин Ю.Д. Поверхностный слой и эксплуатационные свойства деталей машин. М.: МашиностроениеЮ, 1988.240с.
9. Скубачевский Г. С. Авиационные газотурбинные двигатели: Учебник для студентов авиационных вузов. М.: Машиностроение, 1969—544 с.
10. Маталин А. А. Технология машиностроения: Учебник для студентов вузов. М.: Машиностроение, 1985—512 с.
11. http://www.nfmz.ru/lopatki.htm
ОАО «Наро-Фоминский машиностроительный завод» Компрессорные лопатки ГТД
12. http://www.nfmz.ru/lopatki.htm
Д.т.н. Юрий Елисеев, генеральный директор ФНПЦ ММПП "Салют", Перспективные технологии производства лопаток ГТД

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The Important remark!
      During the process of writing, the master’s work hasn’t completed yet. Final completion: December, 2009. The full text of work and materials on the theme could be received from the author or his scientific adviser after the indicated date.

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