Simulation of manufacturing processes and manufacturing chains using finite element techniques

Afazov, Shukri (2009) Simulation of manufacturing processes and manufacturing chains using finite element techniques. PhD thesis, University of Nottingham.

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Abstract

This thesis presents work on the simulation of manufacturing chains, simulation of manufacturing processes (casting, forging, shot-peening and heat treatment) and fatigue life prediction by using the finite element method (FEM). The objectives and the contributions of this thesis consist of development of mathematical algorithms and techniques for mapping and transferring FE data (stresses, strains, displacements, etc.) from macro-to-macro and micro-to-macro FE models among different FE solvers and meshes. All these features have been implemented into a new finite element data exchange system (FEDES). FEDES has been developed to simulate manufacturing chains by using FE techniques. Extensive research has been carried out on the simulation of investment casting processes of aero-engine parts under equiaxed and directional cooling. Methodologies for predicting the component life undergoing low cycle fatigue (LCF) and high cycle fatigue (HCF) have been developed. Life prediction based on the effect of the residual stresses obtained from micro machining and shot-peening processes has been investigated.

FEDES has been used to simulate two manufacturing chains where the residual stresses and the distortions after each manufacturing process have been passed to the next process of the chain. Manufacturing chain simulation including casting, forging and heat treatment has been carried out on a simple parallelepiped geometry. A second manufacturing chain simulation has been performed on an aero-engine vane component which includes the following manufacturing processes: metal deposition, welding, heat treatment, machining and shot-peening. An investment casting simulation under equiaxed cooling of the bottom core vane (BCV) component of the aero-engines vane has been performed. The gap formation and the gap conductance have been studied and implemented in the analyses. The main goal is to investigate the residual stresses in the BCV cast with Inconel 718 material. Two FE solvers (ABAQUS and ProCAST) have been used for validation purposes. An investment casting simulation under directional cooling in a Bridgman furnace of a high pressure turbine blade (HPTB) with CMSX-4 material has been carried out. The effect of the withdrawal velocity on the temperature and the residual stresses of the HPTB cast has been investigated.

Item Type:Thesis (PhD)
Supervisors:Becker, A.A.
Hyde, T.H.
Faculties/Schools:UK Campuses > Faculty of Engineering > Department of Mechanical, Materials and Manufacturing Engineering
ID Code:827
Deposited By:Dr Shukri Afazov
Deposited On:09 Dec 2009 11:02
Last Modified:06 Dec 2011 09:36

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