Application of additive manufacturing to 30CrMnSiA high speed wind tunnel test model design and fluid-structure interaction analysis
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摘要: 增材制造技术可针对任意复杂形状的零件进行加工，制造周期和成本较低，具有传统机械切削加工所不具备的独特优势，在风洞试验模型制造中具有广泛的应用前景。针对高速风洞模型加工中常用的30CrMnSiA材料，开展了金属粉末制备、检测及材料试件的制造研究，在此基础上，利用测试件数据作为材料性能输入参数，结合增材制造工艺，设计了机翼为中空结构的AgardB模型，利用Ansys有限元分析软件，进行了该模型流固耦合仿真分析，并开展了优化设计，结果表明，中空机翼的模型结构能够满足高速风洞试验要求。Abstract: Additive manufacturing technology can be processed in any complex shape parts. The short manufacturing cycle and low cost are its unique advantages compared to the traditional machining, and thus it has wide application prospects in the wind tunnel test model manufacture. In view of the material 30CrMnSiA commonly used in the high speed wind tunnel model processing, the metal powder preparation, detection and material specimen manufacture are studied. On this basis, with test piece data as a yardstick for material performance, an AgardB model with hollow airfoil is designed based on the additive manufacturing process. Moreover, fluid-structure interaction analysis is conducted for the model using Ansys and the optimal design is carried out. The results indicate that the model structure can meet the requirement of high-speed wind tunnel testing.
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图 4 射频等离子体球化技术形成的球形粉微观结构对比
Fig. 4 Comparison of spherical powder microstructure formation of RF plasma spheroidization technology
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图 5 30CrMnSiA球化粉末粒径分布
Fig. 5 Particle size distribution of 30CrMnSiA spheroidization powder
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图 11 不同激光功率和曝光时间条件下增材制造件的相对致密度分析
Fig. 11 Relative density of additive manufacturing test specimen made by different laser powers and exposure times
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图 28 壁厚1.5mm空心翼模型总变形图
Fig. 28 The total deformation of 1.5mm wall thickness hollow wing model
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图 29 壁厚1.5mm空心翼模型von-Mises应力云图
Fig. 29 The von-Mises stress of 1.5mm wall thickness hollow wing model
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图 30 壁厚1.5mm空心翼模型von-Mises应变云图
Fig. 30 The von-Mises strain of 1.5mm wall thickness hollow wing model
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图 31 壁厚0.8mm空心翼模型总变形图
Fig. 31 The total deformation of 0.8mm wall thickness hollow wing model
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图 32 壁厚0.8mm空心翼模型von-Mises应力云图
Fig. 32 The von-Mises stress of 0.8mm wall thickness hollow wing model
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图 33 壁厚0.8mm空心翼模型von-Mises应变云图
Fig. 33 The von-Mises strain of 0.8mm wall thickness hollow wing model
表 1 常用高能束增材制造技术特点对比
Table 1 Comparison of commonly used high energy beam additive manufacturing technologies
成型技术 适应成型材料 适应成型尺寸 成型精度 应用范围 LENS 金属粉末 大 低，需要3mm左右加工余量 大型难加工金属构件、金属零件修复 EBM 金属粉末 中、小 中 生物医学 SLS 高分子粉末 中、小 高 原型使用 SLM 金属粉末 中、小 高 高精度复杂结构件 
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表 2 30CrMnSiA球化粉末与锻件材料成分对比
Table 2 Composition comparison of spheroidal 30CrMnSiA powder and forging material
化学组分(wt.pct) C Si Mn Cr Ni Co Mo Cu Fe O/ppm GB 0.28~0.34 0.9~1.2 0.8~1.1 0.2~0.5 Balance 球化30CrMnSiA粉 0.25 1.05 0.9 0.54 1.99 0.058 0.48 0.05 Balance 500
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表 3 测试件拉伸性能测试结果
Table 3 Tensile properties results of test specimen
激光功率及试样编号 温度 Rm
/MPaRp0.2
/MPaA
/%E
/GPa180W1# 23 1695 1223 8.1 216 180W2# 23 1486 1170 5.6 204 180W3# 23 1545 1208 6.7 203 180W平均 1575 1200 6.8 207 190W1# 23 1600 1205 5.9 205 190W2# 23 1495 1155 5.8 204 190W3# 23 1527 1190 6.4 199 190W4# 23 1532 1175 6.5 208 190W平均 1539 1181 6.2 204 200W1# 23 1614 1224 8.1 235 200W2# 23 1535 1220 7.1 211 200W3# 23 1510 1167 7.6 202 200W平均 1553 1204 7.6 216
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表 4 30CrMnSiA材料属性
Table 4 30CrMnSiA material performance parameters
材料 Rm
/MPaRp0.2
/MPaE
/GPa密度ρ
/(kg·m-3)30CrMnSiA 1080 835 196 7928.6 增材制造30CrMnSiA 1575 1200 207 7928.6
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表 5 流固耦合计算结果
Table 5 The result of fluid-structure interaction
实心翼模型 壁厚1.5mm空心翼模型 壁厚0.8mm空心翼模型 最大允许值 von-Mises应力/MPa 5.515 7.377 7.961 33.33 von-Mises应变 2.558×10-5 3.429×10-5 3.829×10-5 -- 最大变形/mm 0.0752 0.0903 0.0985 0.1361
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