An Increase in the Energy Efficiency of Axial Turbines by Ensuring Vibration Reliability of Blade Milling

Abstract

Ensuring the vibration reliability of power equipment is one of the fundamental problems in modern power machinery. This problem has become more critical due to a permanent increase in the machining performance of high-speed milling of axial turbine blades. This article aims to identify reliable vibration parameters for high-speed milling of turbine blades to increase the energy efficiency of gas and steam turbines. For this purpose, mathematical models of free and forced oscillations of turbine blades during machining were developed. As a result of considering experimental and finite element analysis data, critical frequencies and corresponding mode shapes of free oscillations were identified using regression procedures by the best fit of analytical and empirical approaches. Additionally, after considering the forced oscillations of blades during high-speed machining, the magnitude of the specific cutting force and external damping ratio in the system ‘axial turbine blade and milling head’ were evaluated. The resulting magnitude of forced oscillations during machining was calculated. Finally, the amplitude–frequency response was also assessed, considering the machining parameters. Overall, the proposed methodology increases energy efficiency due to a decrease in the obtained machining quality of turbine blades.

Prospects for the Development of Process Equipment in Aggregate-Modular Design for Sustainable Mechanical Engineering

“…The main advantages of these machines are their high technological flexibility and the ability to fully automate the work cycle. However, such equipment also has significant disadvantages -these machines are quite expensive and, despite the increasing use of high-speed machining [4,5], provide productivity growth in comparison with universal machines with manual control mainly due to automation of auxiliary works and intensification of processing conditions (according to some sources [6,7] by 1.5...2.8 times). Intensification of processing conditions in this case requires the use of special tools and increased stiffness of machine structural elements, which, in turn, leads to an increase in the technological cost of processing.…”