Component Design Optimization by Integration and Automation of Process and Life Modeling

The residual stress generated through the manufacturing processes of the jet engine components plays an important role in determining the number of allowable hours and/or cycles accrued during a components life cycle.  The heat treatment, machining and pre-service conditioning variables contribute to the magnitude and location of residual stresses formed during the manufacturing process. Such variables have traditionally not been optimized for maximum life due to the lack of time sensitive, accurate and process modeling design tools. However, increasing demands for high speed – high temperature disks has necessitated advanced, multi-disciplinary modeling tools and processes in order to deliver high performance, robust and cost favorable solutions. Component process modeling that considers disk stresses through heat treatment, machining, pre-service conditioning and design operation have been linked and automated in order to maximize service life. A sample high stress – high temperature disk is presented that illustrates integration of process modeling with component design.