LOFAMO Development of a local fatigue model of machining affected surface layers that includes surface integrity and mechanical properties

LOFAMO 开发加工受影响表面层的局部疲劳模型，包括表面完整性和机械性能

• 批准号: EP/X023281/1
• 负责人: Dirk Engelberg
• 金额: $ 26万
• 依托单位: University of Manchester
• 依托单位国家: 英国
• 项目类别: Fellowship
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FX023281%2F1
• 关键词: LOFAMO; Development; local; fatigue; model

The aim of LoFaMo is to develop a local fatigue model of machined surfaces of nickel alloys for aerospace based on the relationship of surface integrity (SI) and local mechanical properties of the machining-affected layer. Increasingly, aero-engines are required to operate at higher temperatures & efficiencies, and new heat resistant alloys with unprecedented mechanical properties have been developed to meet those needs. The last stage of the manufacturing chain is usually where the machining operations of critical aero-engine components are carried out. If machining parameters are not selected correctly, the SI of the machined components can be adversely affected and thus, their fatigue life can be dramatically reduced. Although many researchers have studied the SI of heat resistant alloys after machining, very limited studies have so far analysed the effect on fatigue life, and the links between SI parameters and fatigue behaviour are not widely understood and quantified.In this project, specimens will be manufactured at three different surface conditions and the SI of them will be characterised using upfront high-resolution surface mapping using confocal and analytical electron microscopy. Then, innovative in-situ experimental techniques will be used to characterise the mechanical properties locally and fatigue crack-growth: i) in-situ mechanical tests and X-ray diffraction and ii) in-situ mechanical tests and X-ray imaging techniques. Finally, a local fatigue model will be developed integrating in a FEM model the SI and mechanical properties of the machining-affected layer. LoFaMo combines knowledge of manufacturing, material science and advanced experimental techniques to reach the goal. The results will be a step change in the machining of nickel alloys (increased productivity; reduction of scraps in 1%) and will enhance the accuracy of predictive models to produce more efficient designs (towards the European Green Deal Strategy) and extended service life.

LoFaMo的目的是基于表面完整性（SI）与加工影响层局部力学性能的关系，建立航空镍合金加工表面的局部疲劳模型。越来越多的航空发动机需要在更高的温度和效率下运行，而具有前所未有的机械性能的新型耐热合金已经被开发出来以满足这些需求。制造链的最后阶段通常是关键航空发动机部件的加工操作。如果加工参数选择不正确，则会对加工部件的SI产生不利影响，从而大大降低其疲劳寿命。尽管许多研究者对耐热合金加工后的SI进行了研究，但迄今为止分析其对疲劳寿命影响的研究非常有限，SI参数与疲劳行为之间的联系也没有得到广泛的理解和量化。在这个项目中，样品将在三种不同的表面条件下制造，它们的SI将使用共聚焦和分析电子显微镜的前高分辨率表面映射来表征。然后，将使用创新的原位实验技术来表征局部力学性能和疲劳裂纹扩展：i)原位力学测试和x射线衍射；ii)原位力学测试和x射线成像技术。最后，将加工影响层的SI和力学性能集成到有限元模型中，建立局部疲劳模型。LoFaMo结合了制造知识，材料科学和先进的实验技术来实现目标。结果将是镍合金加工的一个步骤变化（提高生产率；减少1%的废料），并将提高预测模型的准确性，以生产更有效的设计（朝着欧洲绿色交易战略）和延长使用寿命。

项目成果

Correcting distortions of thin-walled machined parts by machine hammer peening

通过机锤喷丸校正薄壁机加工零件的变形

• DOI: 10.1016/j.cja.2023.10.023
• 发表时间: 2023
• 期刊: Chinese Journal of Aeronautics
• 影响因子: 5.7
• 作者: MADARIAGA A