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Analysis and design optimization of double-sided deep cold rolling process of a Ti-6Al-4V blade

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Abstract

Deep cold rolling (DCR) is a promising mechanical surface treatment which can be effectively used to improve the fatigue life of components by introducing deep and high beneficial compressive residual stresses on the surface and sub-surface layers. However, the application of conventional DCR on thin-walled geometries such as compressor blades can be very challenging as the applied load can damage the component. Double-sided deep rolling on thin-walled components has been proven to be a viable alternative solution as both sides of the component are treated simultaneously which thus decreases the risk of component distortion. In this study, a high-fidelity non-linear finite element model has been developed to simulate the double-sided DCR process on thin Ti-6Al-4V plate and to predict the residual stress profile introduced by the process and after thermal relaxation due to subsequent exposure to high temperature. The accuracy of the developed finite element model is validated by comparison with the experimental measurement available in the literature. Response surface method (RSM) has then been carried out on results obtained by the high-fidelity FE model to develop predictive analytical models to approximate residual stress profiles induced by the process. The developed analytical models can efficiently replace FE models to perform sensitivity analysis and design optimization of process parameters. Load distribution at high stress areas of a generic compressor blade is considered to formulate a design optimization problem of double-sided DCR process in order to achieve optimal residual stress distributions at room temperature and after thermal relaxation at elevated temperature of 450 °C.

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Authors and Affiliations

  1. Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, Montreal, Quebec, H3G 1M8, Canada

    Armin Hadadian & Ramin Sedaghati

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  1. Armin Hadadian
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  2. Ramin Sedaghati
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Correspondence to Ramin Sedaghati.

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Hadadian, A., Sedaghati, R. Analysis and design optimization of double-sided deep cold rolling process of a Ti-6Al-4V blade. Int J Adv Manuf Technol 108, 2103–2120 (2020). https://doi.org/10.1007/s00170-020-05481-w

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  • DOI: https://doi.org/10.1007/s00170-020-05481-w

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