Residual stresses of turbine blade root produced by creep-feed profile grinding: Three-dimensional simulation based on workpiece–grain interaction and experimental verification. (February 2021)

• Record Type: Journal Article
• Authors: Kuang, Weijie; Miao, Qing; Ding, Wenfeng; Zhao, Yanjun; Zhao, Zhengcai
• Is Part Of: Journal of manufacturing processes. Volume 62(2021)
• Page Start: 67
• Page End: 79
• Publication Date: 2021-02
• Subjects: Residual stresses -- Creep-feed profile grinding -- Finite element simulation -- Workpiece-grain interaction -- Turbine blade root -- Single-crystal nickel-based superalloy; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2020.11.045
• Languages: English
• ISSNs: 1526-6125

Abstract

Abstract: Grinding-induced residual stresses have an important influence on the antifatigue property of turbine blade roots. The conventional finite element (FE) simulation model based on workpiece-tool interaction cannot accurately predict the grinding-induced residual stresses of turbine blade root of DD6 single-crystal nickel-based superalloy. Therefore, in this work, a new thermal-mechanical FE model considering the intensive workpiece–grain interaction was developed to predict the distribution of grinding-induced residual stresses. Furthermore, the grinding temperature, the instantaneous stresses generated during the creep-feed profile grinding operation, and the residual stresses generated after grinding were simulated and verified experimentally. Compared with the simulated results obtained with the conventional model, those obtained with the new model agreed well with the experimental results. By using the new model, the average errors between the simulation and experiment of less than 16 % and 20 % for the grinding temperature and residual stress were obtained, respectively. Moreover, the grinding-induced residual stresses in the peak regions of the blade root workpiece were generally compressive (e.g., from −150 to −100 MPa along the vertical grinding direction ([010] crystal orientation of DD6 alloy), and from −200 to −150 MPa along the parallel grinding direction ([001] crystal orientation of DD6 alloy), while they were transformed gradually to the tensile stresses in the adjacent valley regions.