The finite element method is a powerful tool for predicting welding distortion. However, the mechanical phenomena are strongly non-linear and transient and thus, thermo-elastic-plastic finite element analyses of the phenomena require very long computational time. To overcome this problem, an interactive substructure method was developed as an approach to reduce the computational time in three-dimensional analyses. In this paper, in order to confirm calculation efficiency for a large scale problem, a pipe model with 538 200 degrees of freedom was computed. Furthermore, the residual distortion in an engine component was computed and the applicability of the calculation for problems in welding practices was demonstrated.
Finite element method is a powerful tool for predicting welding distortion. However, the mechanical phenomena in welding are strong non-linear transient problems and thermal-elastic-plastic FE analysis requires very long computational times. To overcome this problem, an interactive substructure method is developed as a method to reduce the computational time in three-dimensional analysis. In this paper, in order to confirm calculation efficiency for a large scale problem, calculation of the pipe model with 538,200 degree of freedoms is performed. Further, calculation of the residual distortion in engine component is performed and its applicability for practical problems is demonstrated.
The future aero engines expected to have the best fuel efficiency are those with the open rotor propulsion system. It has two rows of propellers rotating in opposite directions. The rotational speeds of the propellers are reduced by a power gearbox. The power gearbox is designed as a differential planetary gear system with double helical teeth. The gearbox for aero engines needs to be lightweight and highly reliable. Misalignment on the gear pair affects adversely the reliability of the gears. The misalignment analysis of the power gearbox based on finite element analysis was carried out. The inclination of the planet spindles associated with the twisting deformation of the planet carrier was identified as the major cause of the misalignment. We developed an innovative design method to achieve the low misalignment and lightweight at the same time by optimizing the stiffness balance of the planet carrier. The optimization analysis was carried out extensively in the design work. The planet carrier design was named Analysis Configured Engineering planet Carrier (ACE CARRIER). A stress measurement was planned to validate the design concept of the ACE CARRIER. A test gearbox was manufactured.
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