Structural Analysis And Optimization Design Of Inertial Friction Welder For Aeroengine

The quality of aero engines,which are the focus of research in the field of aviation,determines the technological level of the country in the field of aviation.The aero-engine is called the "heart" of the aircraft,providing power on the one hand,and advancing the progress of the aviation industry on the other.Inertial friction welding machine as an advanced solid-phase welding method,with its own unique advantages widely active in the aerospace field,to become the key technology for the development of aircraft engines.But the domestic friction welding technology is now weak,large-scale equipment is lacking,there is an urgent need to develop a large tonnage of high-precision heavy inertia friction welding machine related research.In order to improve the comprehensive performance of the inertial friction welding machine,this paper on an inertial friction welding machine structural analysis and optimization design,to find the best structure to meet the design index requirements,the specific research is as follows:(1)According to the basic requirements of the friction welding machine design and the principles and characteristics of friction welding,determine the welding parameters and design indicators of the inertial friction welding machine,design the overall structure of the inertial friction welding machine and establish a three-dimensional model of the whole machine;(2)Multi-objective optimization design of the bed structure of the welder using the compromise planning method,establishing a mathematical model of the compromise planning method based on the two objectives of maximum stiffness and maximum inherent frequency,combining the compromise planning method and finite element simulation,multi-objective topology optimization of the bed structure,and determining the structural form of the bed through the optimized material distribution;using the method of sensitivity analysis,determining the key dimensions of the bed,and obtaining the optimal dimensions of each part of the bed through multi-objective dimensional optimization;(3)Topology optimization design of the spindle box structure,while ensuring the stiffness and strength of the spindle box,the mass of the spindle box was reduced by 9.1%to achieve a lightweight design;dimensional optimization of the top forging box,so that the static deformation of the top forging box in the top forging stage was reduced by 3.8%,the maximum stress was reduced by 0.8%,and the mass was reduced by 4.9%,which improved the stiffness and strength of the top forging box and reduced the cost.By comparing the static deformation under different sizes and shapes,a 350 mm diameter round section tie rod was selected;(4)The finite element model of inertia friction welding machine was established,and the finite element simulation analysis of the key components and the structure of the machine was carried out by combining the static and dynamic characteristic analysis theory.The analysis results show that the maximum static deformation of the inertia friction welder is0.368 mm in the top forging stage,among which the deformation in X,Y and Z directions are 0.368 mm,0.052 mm and 0.105 mm respectively,which meets the design index;the firstorder inherent frequency of the modal analysis of the machine is 33.27 Hz,which indicates that the dynamic stiffness is sufficient;the results of the harmonic response analysis of the machine also verify that Inertia friction welding machine can resist the environment it must endure without damage;(5)The advantages and disadvantages of casting,welding and the production process are introduced.A brief analysis of the manufacturing and assembly process of the inertia friction welding machine and the problems that can arise during the assembly process is presented with the spindle box as an example.