航空发动机涡轮预旋喷嘴组件是用于降低进入涡轮的冷却气流相对总温的重要热端功能部件,由多个零件组成,其结构复杂,内部流道加工困难,制造周期长,重量大且加工成本高,是目前航空发动机制造急需解决的难点之一。本文根据涡轮预旋喷嘴组件的结构和加工特性,基于选区熔化制造技术(SLM)对其进行一体化设计、适应增材制造工艺的结构优化设计,并对预旋喷嘴的增材制造过程进行有限元分析,探究预旋喷嘴最优成型方向和零件在增材制造中的变形情况以及空心叶片最佳壁厚,为后续增材制造工艺提供参考。经过评估和后期制造表明,可获得17.08%的轻量化效果,流量偏差由12%优化为5%,缩短了制造周期,达到了轻量化和改善性能的目的。

The pre-swirl nozzles assembly of aero-engine turbine is an important hot end functional component used to reduce the relative total temperature of the cooling air entering turbine rotor blade as much as possible. It is composed of multiple parts, with a complex structure, difficult internal channel processing, long manufacturing cycle, large weight, and high processing cost. It is currently one of the difficulties faced by aero-engine manufacturing. According to the structure and processing characteristics of the pre-swirl nozzles assembly, this paper has conducted integrated design, structural optimization design adapted to additive technology, and internal cavity self-supporting design based on selective melting manufacturing technology (SLM). Finite element analysis has been conducted on the additive manufacturing process of the pre-swirl nozzles to explore the optimal forming direction and wall thickness of vanes of the pre-swirl nozzles, as well as the deformation of the parts during additive manufacturing , to provide reference for subsequent additive manufacturing processes. After evaluation, a weight reduction effect of 17.08% can be obtained, and the flow deviation has been optimized from the original 12% to 5%, shortening the manufacturing cycle and achieving the goal of lightweight and improved performance.