Manufacturing chain simulation of an aero-engine disc and sensitivity analyses of micro-scale residual stresses

This paper reports on the simulation of manufacturing processes and a manufacturing chain for producing an aero-engine disc component. Five manufacturing processes are included in the manufacturing chain and simulated using the finite element method. First, an oil quenching process is performed followed by ageing, macro-scale machining, micro-scale machining and shot-peening. Two FE codes (DEFORM and ABAQUS) are used to simulate the manufacturing processes. The analysis data between each manufacturing process is transferred and mapped to the next process in the chain. The residual stresses from the micro-scale manufacturing processes are mapped to the macro-scale models of the chain. The effects of the mesh density and the element types on the accuracy of the micro-mapping are investigated by performing sensitivity analyses.