Huimin Zhou , Junbo Liu , Shaochen Bao , Shuiting Ding , Guo Li , Guangyao Shao , Ruifeng Li , Gong Zhang , Bo Zhen
{"title":"考虑机械加工引起的随机残余应力的概率风险评估方法","authors":"Huimin Zhou , Junbo Liu , Shaochen Bao , Shuiting Ding , Guo Li , Guangyao Shao , Ruifeng Li , Gong Zhang , Bo Zhen","doi":"10.1016/j.ijmecsci.2024.109785","DOIUrl":null,"url":null,"abstract":"<div><div>The aero-engine disks inevitably have manufacturing-induced anomalies and machining-induced random residual stress (RS) in localized and critical areas, which cause a severe threat to the safety of the aircraft. Traditional structural design of the disks fails to establish a quantitative correlation between the machining process and the failure risk. Therefore, this paper proposes a probabilistic model considering random RS to quantify the influence of machining RS subjected to low-cycle fatigue. The RS dispersion is quantified using a scaling parameter, obtained by X-ray diffraction measurements and orthogonal cutting simulations. The crack life database under varying RSs is established for efficient probability calculations. Results show that the coefficient of variation (COV) of the RS on the same machined surface with the same processing parameters is 7.62 % in the local area and 13.74 % in the whole machined surface. The risk results show that the probability of failure (POF) considering the deterministic RS is 2–4 % lower than the POF without RS, owing to the extension of fatigue life by compressive RS. Furthermore, the POF considering the random RS is almost the same (difference <0.6 %) as the POF considering the deterministic RS because the depth of the machining RS is around 0.2 mm. The proposed method predicts the POF more accurately and is thus valuable for the safety assessment of an aero-engine titanium disk.</div></div>","PeriodicalId":56287,"journal":{"name":"International Journal of Mechanical Sciences","volume":"285 ","pages":"Article 109785"},"PeriodicalIF":7.1000,"publicationDate":"2024-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Probabilistic risk assessment method considering machining-induced random residual stress\",\"authors\":\"Huimin Zhou , Junbo Liu , Shaochen Bao , Shuiting Ding , Guo Li , Guangyao Shao , Ruifeng Li , Gong Zhang , Bo Zhen\",\"doi\":\"10.1016/j.ijmecsci.2024.109785\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"<div><div>The aero-engine disks inevitably have manufacturing-induced anomalies and machining-induced random residual stress (RS) in localized and critical areas, which cause a severe threat to the safety of the aircraft. Traditional structural design of the disks fails to establish a quantitative correlation between the machining process and the failure risk. Therefore, this paper proposes a probabilistic model considering random RS to quantify the influence of machining RS subjected to low-cycle fatigue. The RS dispersion is quantified using a scaling parameter, obtained by X-ray diffraction measurements and orthogonal cutting simulations. The crack life database under varying RSs is established for efficient probability calculations. Results show that the coefficient of variation (COV) of the RS on the same machined surface with the same processing parameters is 7.62 % in the local area and 13.74 % in the whole machined surface. The risk results show that the probability of failure (POF) considering the deterministic RS is 2–4 % lower than the POF without RS, owing to the extension of fatigue life by compressive RS. Furthermore, the POF considering the random RS is almost the same (difference <0.6 %) as the POF considering the deterministic RS because the depth of the machining RS is around 0.2 mm. The proposed method predicts the POF more accurately and is thus valuable for the safety assessment of an aero-engine titanium disk.</div></div>\",\"PeriodicalId\":56287,\"journal\":{\"name\":\"International Journal of Mechanical Sciences\",\"volume\":\"285 \",\"pages\":\"Article 109785\"},\"PeriodicalIF\":7.1000,\"publicationDate\":\"2024-10-12\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"International Journal of Mechanical Sciences\",\"FirstCategoryId\":\"5\",\"ListUrlMain\":\"https://www.sciencedirect.com/science/article/pii/S0020740324008269\",\"RegionNum\":1,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q1\",\"JCRName\":\"ENGINEERING, MECHANICAL\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"International Journal of Mechanical Sciences","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0020740324008269","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}
Probabilistic risk assessment method considering machining-induced random residual stress
The aero-engine disks inevitably have manufacturing-induced anomalies and machining-induced random residual stress (RS) in localized and critical areas, which cause a severe threat to the safety of the aircraft. Traditional structural design of the disks fails to establish a quantitative correlation between the machining process and the failure risk. Therefore, this paper proposes a probabilistic model considering random RS to quantify the influence of machining RS subjected to low-cycle fatigue. The RS dispersion is quantified using a scaling parameter, obtained by X-ray diffraction measurements and orthogonal cutting simulations. The crack life database under varying RSs is established for efficient probability calculations. Results show that the coefficient of variation (COV) of the RS on the same machined surface with the same processing parameters is 7.62 % in the local area and 13.74 % in the whole machined surface. The risk results show that the probability of failure (POF) considering the deterministic RS is 2–4 % lower than the POF without RS, owing to the extension of fatigue life by compressive RS. Furthermore, the POF considering the random RS is almost the same (difference <0.6 %) as the POF considering the deterministic RS because the depth of the machining RS is around 0.2 mm. The proposed method predicts the POF more accurately and is thus valuable for the safety assessment of an aero-engine titanium disk.
期刊介绍:
The International Journal of Mechanical Sciences (IJMS) serves as a global platform for the publication and dissemination of original research that contributes to a deeper scientific understanding of the fundamental disciplines within mechanical, civil, and material engineering.
The primary focus of IJMS is to showcase innovative and ground-breaking work that utilizes analytical and computational modeling techniques, such as Finite Element Method (FEM), Boundary Element Method (BEM), and mesh-free methods, among others. These modeling methods are applied to diverse fields including rigid-body mechanics (e.g., dynamics, vibration, stability), structural mechanics, metal forming, advanced materials (e.g., metals, composites, cellular, smart) behavior and applications, impact mechanics, strain localization, and other nonlinear effects (e.g., large deflections, plasticity, fracture).
Additionally, IJMS covers the realms of fluid mechanics (both external and internal flows), tribology, thermodynamics, and materials processing. These subjects collectively form the core of the journal's content.
In summary, IJMS provides a prestigious platform for researchers to present their original contributions, shedding light on analytical and computational modeling methods in various areas of mechanical engineering, as well as exploring the behavior and application of advanced materials, fluid mechanics, thermodynamics, and materials processing.