The simulation of a complete manufacturing process to produce an aero engine case, including forging, rolling, and machining processes, is analyzed via finite element software. The deformation of the turning and drilling processes is quantitatively studied using the energy principles. Firstly, simulations of multi-stage forging of aero engine case and machining-induced residual stress are conducted and verified via the residual stresses test in order to provide the initial elastic strain energy condition prior to machining processes. The effects of blank forging-induced residual stress and machining-induced residual stress on the deformation of titanium alloys aero engine case are investigated. Secondly, a potential energy expression for the machining processes is developed. The predicted results of turning and drilling simulations indicate that there is an optimal process in which the deformation and potential energy decline rapidly compared with the other processes and finally, gradually stabilize at the end of the process.

Residual stresses (RS) in hot forging severely degrade the machining accuracy and stability of super alloy parts. This is the main reason for deformation during subsequent mechanical machining. RS need recognition, as well as the microstructure and properties achieved by forging. In this study, a simulation and experimental research on the single-pass compression of GH4169 are presented. RS variations with forging temperature, loading speed, and cooling speed are established by finite element (FE) simulation. Based on the FE results, an experiment is conducted at a temperature of 1020$℃$, loading speed of 25 mm/s, and press amount of 16 mm, immediately followed by water cooling. A new layer-stripping method is put forward for the high-efficiency measurement and correction of interior RS. Compared with the traditional strain gauge layer-stripping method, the measurement efficiency of the new layer-stripping method is increased by 10 times. Meanwhile, grain photographs are collected and grain size evolution is summarized; thus, the RS is characterized and evaluated from the angle of grains. It is demonstrated that the RS level rises with the increase in forging temperature, loading speed, and cooling speed, while the cooling method influences both the stress value and distribution. Compressive RS changes to tensile, while the average grain size reduces from the surfaces to the center. In the compressive regions, stress values share the same rules as grain size, while, in the tensile regions, they are contrary. The RS levels are divided according to the grain degree standard. According to the residual stress and grain distribution law of the blank, the optimal position of the part in the blank can be determined. Compared with the center position of the part in the blank, the residual stress of the part is reduced by 70%. The results provide useful strategies for the better design of forging technology, qualification examinations, and subsequent mechanical machining.

Transverse tensile strength of unidirectional (UD) composites plays a key role in overall failure of fiber-reinforced composites. To predict this strength by micromechanics, calculation of actual stress in constituent matrix is essentially required. However, traditional micromechanics models can only give the volume-averaged homogenized stress rather than an actual one for a matrix, which in practice will cause large errors. In this paper, considering the effect of stress concentration on a matrix, a novel micromechanics method was proposed to give an accurate calculation of the actual stress in the matrix for UD composite under transverse tension. A stress concentration factor for a matrix in transverse tensile direction is defined, using line-averaged pointwise stress (obtained from concentric cylinder assemblage model) divided by the homogenized quantity (obtained from a bridging model). The actual stress in matrix is then determined using applied external stress multiplied by the factor. Experimental validation on six UD carbon fiber-reinforced polymer (CFRP) specimens indicates that the predicted transverse tensile strength by the proposed method presents a minor deviation with an averaged relative error of 5.45% and thus is reasonable, contrary to the traditional method with an averaged relative error of 207.27%. Furthermore, the morphology of fracture section of the specimens was studied by scanning electron microscopy (SEM). It was observed that different scaled cracks appeared within the matrix, indicating that failure of a UD composite under transverse tension is mainly governed by matrix failure. Based on the proposed approach, the transverse tensile strength of a UD composite can be accurately predicted.

In the aerospace field, hole burnishing enhancement plays an essential role in improving the service performance of load-bearing holes. To satisfy the assembly accuracy and strength requirements, the structure shape and surface integrity must be considered simultaneously during the enhancement process. The current manufacturing process of hole burnishing has a relatively weak balance between the structure shape and surface integrity; therefore, it is necessary to analyze the mechanism and optimize the parameters to improve the strengthening effect of the holes. In this study, a two-dimensional longitudinal simplified model for the hole burnishing process was established, and the reasons for the surface roughness improvement of the hole wall and material accumulation on the upper surface were analyzed. Experiments were conducted to determine the influence of the burnishing parameters on the structure shape (material accumulation, shape contour, and roundness) and surface integrity (surface roughness, residual stress, and surface hardness), based on the opposite requirements of improving the structure shape and surface integrity for the burnishing depth (BD). The results showed that with an increase in the BD, the structure shape deteriorated, whereas the surface integrity improved. Fatigue behavior verification experiments were conducted, and parameter selection schemes for the collaborative improvement of the structure shape and surface integrity were discussed. For the holes of titanium alloy TB6 (Ti-10V-2Fe-3Al), the fatigue life can be increased by 162% when the BD, spindle speed, and feed rate were 0.20 mm, 200 r/min, and 0.2 mm/r, respectively.