Overview
The objective of this project was the implementation of an integrated simulation chain including pre material characteristics, thermo-mechanical processing (forging and heat treatment) and assessment of microstructure and functional properties for aerospace turbine components.
The integration of different computational results within an interdisciplinary and intercompany design-chain was a challenging task. A fully integrated simulation chain along the supply chain will give unique benefit for product development with respect to time, cost, and quality. This allows an optimisation of the forgings in respect of weight, efficiency and CO2 reduction.
Böhler Schmiedetechnik GmbH & Co KG (BSTG) developed a model for determining the microstructure (e.g. local grain size distribution in a component) from forging and heat treatment simulations. This model was in daily use for thermo-mechanical process design and optimisation of turbine disks. In past, recent and future R&D projects, Böhler Schmiedetechnik had developed models for determining the local functional properties depending on the microstructure. In a further step, aiming at the topic of this proposal, the simulation chain is to be integrated into an industrialised useful format, targeted at customer needs. Suitable strategies and methods for integration of the pre-material characteristics had to be assessed. The quality of the existing models had to be evaluated together with the customer. Comprehensive statistic investigations work was necessary in order to make the usage of the simulated data possible at the customer. Detailed investigations had to be executed to improve and/or generate functional properties models like yield stress, low cycle fatigue and creep models. Interfaces had to be defined and generated. A validation work had to be examined with forged LPT (low pressure turbine) demonstrator disks which show the effectiveness and model capabilities.
Funding
Results
Executive Summary:
The strong need for higher efficiency, reduced CO2 and NOX emissions, weight and noise reduction in aircraft engines led to a demand of optimised lightweight engine disks. The new generation of aircraft engines with their geared turbofan concept fuels this demand. The special design of such engines with their faster rotating low pressure turbine leads to higher loads and therefore requires parts with tailored mechanical properties.
The objective of the project INTFOP was the implementation of an integrated simulation chain for aircraft engine disks including pre-material characteristics, thermo-mechanical processing (i.e., forging and heat treatment) and assessment of microstructure and functional properties. The integration of different computational results within an interdisciplinary and intercompany design-chain was a challenging task. A fully integrated simulation chain along the supply chain gives unique benefit for product development with respect to time, cost, and quality. This allows an optimisation of the forgings in respect of weight, efficiency and CO2 reduction. Böhler Schmiedetechnik GmbH & Co KG (BSTG) has developed a model for determining the microstructure (e.g. local grain size distribution in a component) from forging and heat treatment simulations. This model is in daily use for thermo-mechanical process design and optimisation of turbine disks. In past R&D projects, Böhler Schmiedetechnik has developed models for determining the local functional properties depending on the microstructure.
In this project, the simulation chain was integrated into an industrialised useful format, targeted at customer needs. Suitable strategies and methods for integration of the pre-material characteristics were assessed. In this part of the project, the project partner Bohler Edelstahl GmbH & Co KG, which produces amongst others billets as well as milled semi-final products made of different double or triple melted nickel base alloys, generated valuable input. Furthermore, the quality of the existing models was evaluated together with the customer. Comprehensive statistic investigations work was necessary in order to make the usage of the simulated data possible at the customer. Detailed investigations were executed to improve and generate functional properties models like yield stress, low cycle fatigue and creep models. Interfaces between pre-material supplier, forging house and customer were defined and generated. A validation was examined with forged LPT (low pressure turbine) demonstrator disks which confirmed the effectiveness and capabilities of the implemented simulation chain.