Numerical-experimental correlation of distortions induced by machining process on thin-walled nickel super alloy forged components

Aero Engines main components made by nickel super alloys are mainly obtained by machining of large forged parts. The work piece machining process generates distortions and in some cases they may be relevant. In this contest, in many cases the removed volume in the machining operations represents a large percentage of the forged component in order to obtain the thin-walled wanted geometry. Due to this reason, the residual bulk stresses induced by the process history can lead to significant 3D geometric distortions in the machined component with unacceptable dimensions and shapes of the obtained product for comparison with the wanted geometry. Moreover, it is a matter of fact how, the final component distortions depend by the cutting strategy adopted in the machining process. The experimental study of such cutting strategies on real components are particularly time consuming and costly and for this reason the chance to study the problem using reliable numerical models it is particularly welcome. In the present work authors report the numerical model development to simulate the forging and machining processes needed for the production of an aircraft engine component and the comparison of the obtained results with the ones physically measured from a production batch.