INTFOP · Integrating Forging and Process Simulation for turbine disks

The objective of this project is the implementation of an integrated simulation chain including pre material characteristics, thermo-mechanical processing (forging and heat treatment) and assessment of microstructure and functional properties for aerospace turbine components.The integration of different computational results within an interdisciplinary and intercompany design-chain is a challenging task. A fully integrated simulation chain along the supply chain will give unique benefit for product development with respect to time, cost, and quality. This allows an optimization of the forgings in respect of weight, efficiency and CO2 reduction.Böhler Schmiedetechnik GmbH & Co KG (BSTG) has developed a model for determining the microstructure (e.g. local grain size distribution in a component) from forging and heat treatment simulations. This model is in daily use for thermo-mechanical process design and optimization of turbine disks. In past, recent and future R&D projects, Böhler Schmiedetechnik has developed models for determining the local functional properties depending on the microstructure. In a further step, aiming to the topic of this proposal, the simulation chain is to be integrated into an industrialized useful format, target-aimed to customer needs. Suitable strategies and methods for integration of the pre-material characteristics have to be assessed. The quality of the existing models has to be evaluated together with the customer. Comprehensive statistic investigations work is necessary in order to make the usage of the simulated data possible at the customer. Detailed investigations have to be executed to improve and/or generate functional properties models like yield stress, low cycle fatigue and creep models. Interfaces have to be defined and generated. A validation work has to be examined with forged LPT (low pressure turbine) demonstrator disks which show the effectiveness and model capabilities.""