Abstract
The simulation of a complete manufacturing process to produce an aero engine case, including forging, rolling, and machining processes, is analyzed via finite element software. The deformation of the turning and drilling processes is quantitatively studied using the energy principles. Firstly, simulations of multi-stage forging of aero engine case and machining-induced residual stress are conducted and verified via the residual stresses test in order to provide the initial elastic strain energy condition prior to machining processes. The effects of blank forging-induced residual stress and machining-induced residual stress on the deformation of titanium alloys aero engine case are investigated. Secondly, a potential energy expression for the machining processes is developed. The predicted results of turning and drilling simulations indicate that there is an optimal process in which the deformation and potential energy decline rapidly compared with the other processes and finally, gradually stabilize at the end of the process.
Highlights
Titanium alloys are widely used in the aerospace industry due to their low-density, high strength, toughness corrosion resistance and good high-temperature [1]
A polynomial equation model of residual stress distribution was established by the polynomial fitting method, and the machining distortion of aluminum alloy parts was simulated by the finite element method (FEM) and verified via experiments
The results indicated that heat treatment ameliorates the residual stress of semi-finished products and reduces machining deformation
Summary
Titanium alloys are widely used in the aerospace industry due to their low-density, high strength, toughness corrosion resistance and good high-temperature [1]. A polynomial equation model of residual stress distribution was established by the polynomial fitting method, and the machining distortion of aluminum alloy parts was simulated by the finite element method (FEM) and verified via experiments. Based on the elastic theory, Nervi et al [5] established a mathematical model to predict the machining deformation with the theory of elasticity Both the installation position of the workpiece and the MIRS could causes relatively large deformation of the thin-walled parts. A machining deformation prediction model, which considered multifactor coupling effects, including the initial residual stresses, cutting loads, clamping forces, and MIRS, was established based on the FEM [8]. Predictions of the deformation and strain energy caused by MIRS and FIRS are made at different stages of the material removal. An optimal process route that can effectively control the processing deformation is obtained
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