The present invention relates a method for manufacturing a multi-finger pinned root for turbine blade attached to a turbine rotor and a turbine blade.
The present application claims priority from Japanese Patent application serial No. 2012-79867, filed on Mar. 30, 2012, the content of which is hereby incorporated by reference into this application.
A steam turbine for power generation has a rotary shaft referred to as a turbine rotor which is coupled with turbine blades. The turbine blades rotate the turbine rotor by receiving steam power and cause electric power to be generated. When the turbine rotor rotates, a centrifugal force is generated in each turbine blade, and the centrifugal force is supported where the turbine blade is coupled with the turbine rotor. The turbine blade and the turbine rotor can be coupled using, for example, a pin and finger root form, a straddle mount form, or a fir-tree form. A turbine blade and a turbine rotor coupled in the pin and finger root form each have a fork-shaped part referred to as a fork. The turbine blade and the turbine rotor are coupled using coupling pins inserted in holes formed through them with their forks meshed with each other. When the turbine rotor rotates, the centrifugal force generated in the turbine blade is supported by the coupling pins allowing a high stress to be circumferentially generated over the inner surface of each pin insertion hole. This results in a high risk of fatigue damage to the inner surface of each pin insertion hole. To reduce such a risk of fatigue damage, it is necessary to pay particular attention to the machining accuracy for and the surface finish of each pin insertion hole.
To form a pin insertion hole through a part of a turbine where a turbine rotor and a turbine blade are coupled, a hole is drilled through the part in a state with the turbine rotor fork and the turbine blade fork meshed with each other, then each drilled hole is reamed to achieve a target fitting accuracy and surface finish. This method of forming a pin insertion hole in which first a hole is drilled and next the drilled hole is reamed is described, for example, in Japanese Unexamined Patent Publication No. Sho 60(1985)-222503 (PTL1).
[PTL 1] Japanese Unexamined Patent Publication No. Sho 60(1985)-222503
[NPTL1] Walter D. Pilkey, “Peterson's Stress Concentration Factors,” (USA), 2nd Edition, Wiley-Interscience, Apr. 18, 1997
For thermal power generation plants, there are cases in which, with an intention of adopting larger turbine blades, a high-strength blade material is used. In such cases, with a high-strength material having high notch sensitivity, it is necessary to pay particular attention to the surface finish of pin insertion holes so as to minimize their surface ruggedness.
If, while the surface of a drilled hole is being finished by reaming, chips attach to edges of the reamer, they detrimentally affect, as built-up edges, the finish of the surface being reamed. Therefore, while reaming a hole, air or cutting oil is kept applied to the hole portion being reamed so as to cause chips generated by reaming to be removed from the hole.
There are, however, cases in which fine chips generated during reaming of a pin insertion hole are left attached to edges of the reamer without being removed from the pin insertion hole and such chips result in leaving fine scratches on the inner surface of the pin insertion hole when the reamer is removed from the pin insertion hole. According to the study made by the present inventors, in cases where a part through which pin insertion holes are formed is made of a high-strength material, even fine scratches left on the inner surface of a pin insertion hole when the reamer is removed from the pin insertion hole can detrimentally affect the fatigue strength of the part.
In the existing methods, including the one disclosed in PTL 1 (Japanese Unexamined Patent Publication No. Sho 60(1985)-222503), for forming a pin insertion hole through a turbine blade, no consideration is given to scratches generated by fine chips on the inner surface of a pin insertion hole when the reamer is removed from the pin insertion hole. When an existing method for forming a pin insertion hole through a turbine blade is applied, as it is, to a turbine blade made of a high-strength material with high notch sensitivity, the detrimental effect of scratches formed on the inner surface of a pin insertion hole cannot be prevented.
An object of the present invention is to provide a method for manufacturing a multi-finger pinned root and a turbine blade, the method being applicable with high strength reliability even to a turbine blade which is made of a high-strength material and which is to be coupled to a rotor in a pin and finger root form.
To achieve the above object, the present invention provides a method for manufacturing a multi-finger pinned root for turbine blade attached to a turbine rotor, the multi-finger pinned root coupling the turbine blade and a rotor disc of the turbine rotor. In the method, after a pin insertion hole is reamed, the reamer used is removed from the pin insertion hole while being rotated.
The present invention also provides a turbine blade in which a scratch formed on the inner surface of a pin insertion hole formed through a root portion to be pin-coupled to a rotor disc is inclined with respect to the axial direction of the pin insertion hole.
According to the present invention, the direction of a scratch formed on the inner surface of a pin insertion hole and the direction of tensile stress generated on the inner surface of the pin insertion hole are close to be parallel to each other, so that fatigue strength reduction due to the scratch can be inhibited.
An embodiment of the present invention will be described below with reference to drawings.
The blade fork 5 of the turbine blade 2 and the rotor fork 7 of the turbine rotor 3 are arranged to mesh with each other. The blade fork 5 and the rotor fork 7 have pin insertion holes 8 extending through them in the rotor axis direction. Coupling pins 9 are inserted into the pin insertion holes 8 thereby filling the pin insertion holes 8 and fixing the turbine blade 2 to the turbine rotor 3.
When the turbine rotates causing a centrifugal force in a radial direction (an upward direction as seen in
The turbine blade is made of a high-strength material, for example, a Ti alloy which allows the turbine blade to have a greater length. A high-strength steel (with a tensile strength of 1300 MPa or higher) may also be used as a high-strength turbine blade material. Since, as mentioned in the foregoing, a high-strength material has high notch sensitivity, the surface finish of a turbine blade made of a high-strength material requires particular attention to be paid thereto.
To form the pin insertion holes 8 through the turbine blade attachment base, holes are drilled through the turbine rotor 3 and the turbine blade 2 with their forks meshed with each other, then the drilled holes are reamed to achieve target fitting accuracy and surface roughness.
When chips generated during reaming attach to edges of the reamer 21, they detrimentally affect, as built-up edges, the surface of the pin insertion hole being reamed. To prevent this from occurring, the air blower 23 keeps blowing air into the pin insertion hole being reamed so as to remove chips 11 from the pin insertion hole 8. Still, there are cases in which, for example, a fine chip 12 remains, without being blown off, attached to an edge of the reamer 21 as shown in
The depth a of the scratch is up to about 10 μm. In the case of steam turbines used at nuclear power generation plants, turbine blades are made of steel with a tensile strength lower than 900 MPa, and the fatigue strength of such turbine blades are not detrimentally affected by scratches with a depth of up to about 10 μm. In the case of thermal power generation plants, however, there are cases in which, with an intention of adopting larger turbine blades, a higher-strength blade material is used. In the present embodiment, turbine blades made of a high-strength material are used so as to allow the turbine blades to be made larger. Since high-strength materials have high notch sensitivity, their fatigue strength can possibly be affected detrimentally even by scratches 13 with a depth of about 10 μm generated by fine chips 12.
First, with reference to
With the ratio of depth to width (a/h) of the scratch 13 generated by a chip being about 0.1:
Kt=1+4×0.1=1.4 (2)
This follows that the stress at the bottom 14 of the scratch 13 generated by a chip is about 1.4 times as large as the stress generated with no scratch present.
Next, with reference to
With the ratio of depth to width (a/h) of the scratch 15 generated by a chip also being about 0.1 and the inclination θ of the scratch 15 being 60°:
Kt=1+4×0.1×0.5=1.2 (4)
As described above, in the present embodiment in which the reamer used to ream a pin insertion hole is removed while being rotated causing a scratch generated by a chip to be inclined by 60° as θ with respect to the axial direction of the pin insertion hole, the stress concentration factor Kt is reduced to 1.2 compared with 1.4 obtained in a related-art case in which the reamer is removed without being rotated causing a scratch generated by a chip to run along the axial direction of the pin insertion hole. Namely, the stress at the bottom of a scratch can be reduced by 14% (1−1.2/1.4≈0.14).
Generally, a fatigue crack grows perpendicularly to the direction of stress. Therefore, in the related-art case, if a crack is generated in the scratch 13, it will grow along the bottom 14 of the scratch subjected to a high stress. In the present embodiment, if a crack is generated in the scratch 15, it will grow following a path which deviates from the scratch 15 generated by a chip, so that the stress at the front end of the growing crack is smaller than in the related-art case. This is an effect lengthening the fatigue life of the turbine blade.
According to the present embodiment, the inclination angle θ of the scratch is 60°, so that the direction of the scratch on the inner surface of the pin insertion hole and the direction of tensile stress generated on the inner surface of the pin insertion hole are adequately close to be parallel to each other. This makes it possible to effectively inhibit the fatigue strength reduction caused by the scratch. As seen from
More generally, a target value of Kt dependent on the situation is determined and the minimum value of θ to be achieved to realize the target value of Kt is determined as expressed by expression (5) based on expression (3).
As described above, an appropriate value of inclination θ of the scratch 15 required to realize a target value of Kt can be obtained using expression (5).
Expression (5) can be satisfied by appropriately setting conditions for removing the reamer 21. Where the radius of the reamer 21 is r (mm), the rotation speed of the reamer 21 being removed is f (rpm), and the reamer removal speed is v (mm/min), expression (6) is established representing the relationships between the scratch inclination angle θ, the amount of reamer movement per minute in the rotational direction, and the amount of reamer movement per minute in the removal direction as shown in
Based on expressions (3), (5), and (6), the conditions for removing the reamer 21 without allowing stress concentration factor Kt to exceed a target value are represented by expression (7).
Where a/h=0.1 and Kt=1.2, expression (7) becomes as follows.
When the radius r of the reamer 21 is 6 mm, the rotational speed f at which the reamer is removed and the removal speed v of the reamer are required to satisfy the following expression.
Thus, removing the reamer 21 based on the conditions satisfying expressions (7), (8), and (9) makes it possible to keep the stress concentration factor Kt on a crack below a target value. Therefore, according to the present embodiment, high strength reliability can be obtained even in cases where a pin and finger root form is used for turbine blades made of a high-strength material with high notch sensitivity.
There are cases in which, when a hole is drilled, a burr removing drill is used in addition to a drill used to form the hole. The burr removing drill is withdrawn from the drilled hole while being rotated so as to remove burrs. Unlike in drilling, however, burr generation is not conspicuous in reaming due to the nature of the process. Generally, therefore, reamers used for reaming are removed without being rotated.
Next, inspection of a crack generated on the inner surface of a pin insertion hole will be described.
In the present embodiment, after a pin insertion hole is reamed, the reamer used for reaming is removed and the inner surface of the pin insertion hole is observed to make sure that the angle θ formed between the scratch generated on the inner surface of the pin insertion hole and the axial direction of the pin insertion hole is not smaller than a predetermined angle.
The microscope 40 is comprised of a rod-like scope body 41 and an image processing/display device 45. The scope body 41 is provided, at a front end portion thereof, with two cameras 42. For each of the cameras 42, a light 43 to be used as a light source for shooting the inner surface of a pin insertion hole is provided close to the camera 42. The scope body 41 is further provided with two rubber tires 44, one forwardly of the cameras 42 and the other rearwardly of the cameras 42. To inspect a pin insertion hole 8, the scope body 41 is inserted into the pin insertion hole 8, the inner surface of the pin insertion hole 8 is shot by the cameras 42, and the inner surface of the pin insertion hole 8 thus shot is displayed on the image processing/display device 45.
Referring to
The rubber tires 44 allow the cameras 42 to shoot the inner surface of the pin insertion hole 8 without coming into direct contact with the inner surface. The rubber tires 44 allow the scope body 41 to be moved into and out of the pin insertion hole 8 smoothly without injuring the inner surface of the pin insertion hole 8.
As described above, the microscope 40 makes it possible, just by inserting the scope body 41 into the pin insertion hole, to quickly observe the inner surface of the pin insertion hole 8 without injuring the pin insertion hole 8. This embodiment makes it possible to determine, after the reamer is removed from a pin insertion hole, whether or not any scratch which might detrimentally affect the fatigue strength of the turbine blade is present on the inner surface of the pin insertion hole. Namely, when the angle θ formed between a scratch on the inner surface of a pin insertion hole and the axial direction of the pin insertion hole is smaller than a predetermined value (for example, when θ is such that a target stress concentration factor Kt cannot be realized based on the foregoing expression (5)), it is determined that the scratch may detrimentally affect the fatigue strength of the turbine blade. Based on this criterion, whether such a scratch is present on the inner surface of the pin insertion hole is determined. If such a scratch is found on the inner surface of the pin insertion hole, the scratch is removed, for example, by grinding.
Number | Date | Country | Kind |
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2012-079867 | Mar 2012 | JP | national |