The article describes the development of mathematical models and user environment in the APD language which are based on the finite element system solver and allow for the SLM physical process numeric modelling with the required accuracy. The main task is to evaluate the final shrinkage and residual strength of the blanks of gas turbine parts for optimizing the technological process of production. The activities on introducing pre-distortions into the part geometry were performed to compensate for thermal deformation during the growth process; the part with pre-distortion was produced and controlled.
This paper presents the results of software (ANSYS software) improvements specific for modeling the physical process of SLM (Selective Laser Melting). Improvement goal was to create a set of mathematical models and user environment (a set of APDL programs) based on the ANSYS finite element analysis system solver, allowing to perform the technological procedure of physical SLM process numerical modeling to the required degree of precision with an estimate of the final distortion and residual stresses of gas turbine engine parts to optimize the manufacturing process.
The paper studies the matters of numeric simulation of the processes of casting, crystallizing and cooling down to room temperature, and addresses the related problem of the stress-strain state of the casting process in manufacturing the cast parts of a gas turbine engine. The influence of the technological parameters of casting onto the development of the deformation defects was evaluated. The works were performed on incorporating predeformation into the burn-out model for compensating temperature deformations during casting, and on production and control of the above casting with predeformation.
The article presents the simulation of part distortion during laser metal deposition and a comparison of its results with the deposition performed in experiment. A numerical methodological approach to simulation is viewed which involves dividing the deposited material into primitive solids and further heating and cooling of each primitive solid along the deposition trajectory instead of simulating a moving heat source.
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