تحليل اجزاء محدود فرآيند نورد حلقه در شكل دهي ديسك هاي كمپرسور موتور هواپيماي جت به منظور طراحي شكل دهي

چكيده انگليسي :

FE Analysis of Forming Process of Jetairplane s Compressor s Disks in Order to Design Ring Rolling Forming Stages Amir Hossein Gheisari a Gheisari@me iut ac ir Date of Submission 05 09 2011 Department of Mechanical Engineering Isfahan University of Technology Isfahan 84156 83111 IranDegree M Sc Language FarsiSupervisor Dr Mohammad Reza Forouzan forouzan@cc iut ac ir Dr Abdol Ali Maracy a maracy@mut es ac irAbstractHot ring rolling is an advanced incremental forming process with coupled thermo mechanical effect In recent years with the rapidly increasing demand of aviation and aerospace industries for high quality large seamless rings ofhigh strength material like titanium alloy hot ring rolling has become a preferred processing method formanufacturing such rings due to its advantages such as a considerable saving of energy and material costs highquality high efficiency and low noise In this thesis the hot ring rolling of some titanium alloy parts wasinvestigated using theoretical analysis based on FE methods The main purpose of this project is to achieve themanufacturing technology of front and rear spool of jet motors using the ring rolling process These parts are locatedin jet motor s compressor and turbine sequentially and the motor s blades stand on these two parts The main part of this thesis includes non linear finite element analysis of ring rolling via ABAQUS simulationsoftware This analysis was executed for elastic plastic rings using 3D mechanical thermal coupled models Thepresented analysis is unique in many viewpoints such as complexity in shape of samples the special geometry ofthe working rolls complex movement of guide rolls and the time consuming simulation This thesis has been led tothe development of two new approaches in the physical simulation of guide rolls and the simulation of complexparts using limited hardwares The absence of guide rolls in the FE simulation of the ring rolling process leads to the deflection of the ring duringthe process and eventually suspending the simulation Results prove the necessity of using guide rolls for stabilizingthe operation The first approach is capable of physically simulating the guide roll similar to the machine structure ofthe ring rolling system and calculating the approximate movement path of the guide roll The forces and moments ofthe guide rolls are then calculated based on the approximated path This approach requires further development foroptimizing the movement path of the guide roll concluding in the optimization of the forces and moments of theguide roll The maximum error of this approach is about 6 in calculating the roll force and 13 in calculating theside spread with reduction The results show that including the guide roll in the simulation drastically improves theaccuracy of the outputs this approach can simulate the guide rolls for most complicated rings and has lowcomputational time compared to other available methods The second approach also simulates the ring rolling process uses separating of the ring in appropriate sections separately FE simulating of each section and then gathering results This approach is suitable for large number of thecalculations and the inability of the available hardware for accomplishing the integrated simulation because of thelow memory The results show maximum of 13 5 error for this approach The simulation results of these two parts including the forces and moments of the work rolls provide a guide fordesigning a ring rolling machine for manufacturing these two parts using appropriate reliability factor Thecalculated parameters also provide a guide for rolling the parts by this machine Key WordsHot Ring Rolling FE Analysis Guide Roll Section Separation Method Complex Profile

قيصري، امير حسين

تحليل اجزاء محدود فرآيند نورد حلقه در شكل دهي ديسك هاي كمپرسور موتور هواپيماي جت به منظور طراحي شكل دهي

نورد حلقوي گرم , غلتك هاي راهنما , روش تقسيم مقطع , مقاطع پيچيده