面向航空发动机高温合金盘件长疲劳寿命的加工表面状态与性质演化及调控机制研究

To respond the 2018 project guideline issued from National Natural Science Foundation of China (2018-87), and to conjugate with the development of aeroengine componts machining technology from satisfying the requirements of design macro-geometric dimensions to anti-fatigue manufacturing, the research idea of placing the safety service of components in its manufacturing process is put forward in this application. The long fatigue life of aeroengine superalloy discs machining technology will be proposed. The machined surface state and evolution of properties and regulation mechanism will be explored. Through the multi-disciplinary integration of manufacturing science and materials engineering, the mapping relationship among machining process, machined surface state as well as properties, physical and mechanical properties of surface materials and service efficiency of machined parts in the multi-process manufacturing of key components such as Ni-base superalloy turbine disk and labyrinth disk of aeroengine are investigated. The relationship between machining process parameters and fatigue life of machined components under multi-physical fields actions is revealed. The multi-scale evolution and transfer mechanism of machined surface integrity are described. The influence of machining process on the physical and mechanical properties on machined surface materials is expounded. The safe service life of key components of aeroengine can be improved by controlling the machining process, and the shape-property synergy of key components of aeroengine superalloy is realized. The research results are helpful to establish the theory of integrated material-manufacturing-service. The research can also provide technical guidance for the development of new manufacturing technology and equipment for anti-fatigue processing.

根据国科金发计〔2018〕87号2018年度项目指南，结合航空发动机机械加工技术从满足设计宏观几何尺寸的要求发展为抗疲劳制造的需求，提出将构件安全服役置于其制造过程的研究思路，开展面向航空发动机高温合金盘件长疲劳寿命的加工表面状态与性质演化及调控机制研究。通过制造、材料等学科交叉融合，探究航空发动机镍基高温合金涡轮盘、篦齿盘等关键构件高发失效部位多工序制造过程中“加工工艺-加工表面状态与性质-表面材料物理力学性能-零件服役效能”的映射关系，揭示多物理场作用下高温合金加工表面状态与性质的多尺度演化、传递机制，阐述制造工艺对加工表面材料物理力学性能与服役效能的影响规律，通过加工工艺调控，提高航空发动机关键构件安全服役寿命，实现航空发动机高温合金关键构件制造的形性协同控制的研究目标。研究成果有助于材料-制造-服役一体化制造理论的开辟建立，可为抗疲劳加工制造新工艺与装备的开发提供技术指导。

项目面向航空发动机高温合金盘件长疲劳寿命服役需求，开展加工表面状态与性质演化及调控机制研究并取得系列成果。提出了多物理场作用下高温合金材料的动态热力学性能测试方法，基于切削运动学和动力学原理建立了顺序切削力-热载荷和三维表面形貌预测模型，揭示了高温合金多工序加工表面几何属性与表面材料物理力学性能的演化传递机制；开发了航空发动机典型构件疲劳寿命的形性协同预报与调控技术，搭建了航空发动机高温合金涡轮盘和篦齿盘等特征件疲劳性能测试平台，通过加工工艺调控提高了航空发动机关键构件安全服役寿命，实现了航空发动机高温合金关键构件制造的形性协同控制的研究目标。研究成果有助于材料-制造-服役一体化制造理论的开辟建立，为航空发动机关键构件抗疲劳加工制造新工艺与装备开发提供技术指导。.项目预期目标已顺利完成并取得一系列研究成果，发表SCI学术论文50余篇，SCI他引总计200余次；获得授权国家发明专利13项；项目开展期间培养国家优秀青年科学基金获得者、中国科协青年人才托举工程获得者和山东省优秀青年科学基金获得者等多名青年人才。研究成果已成功应用于中国航发沈阳黎明航空发动机有限责任公司、钢铁研究总院和株洲钻石切削刀具股份有限公司等国内重点制造企业与刀具公司，并与美国罗格斯大学、美国密歇根州立大学、英国思克莱德大学等国际一流高校建立了良好的合作关系；研究团队已建成具有国内外重要影响力的航空发动机关键构件高质高效加工与抗疲劳制造研究平台，形成了典型难加工材料零件的高性能设计制造研究高地。