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Residual stress analysis of the multi-stage forging process of a nickel-based superalloy turbine disc

In order to analyze the multi-stage forging process of a nickel-based GH4169 superalloy (similar to Inconel 718 alloy) aero-engine turbine disc with high efficiency and accuracy, a modified material constitutive law, grid convergence study, and a combined two-dimensional and three-dimensional finite element simulation technology were used to analyze the thermo-mechanical-coupled stress variation during the turbine disc multi-stage forging process with the general-purpose nonlinear finite element software MSC.Marc. The predicted finite element forging residual stresses were tested and verified with the measurement results by the layer removal method; it was found that the constitutive law combined with heat contact properties between dies and material could be used to accurately predict and analyze the turbine disc forging processes. Based on the predicted precise and comprehensive finite element residual stress distributions, the consequent disc anti-fatigue manufacturing technologies could be optimized and improved greatly, which would guarantee the stable manufacturing quality and excellent performance of the aero-engine turbine disc.