Integration of Manufacturing Process Simulation with Probabilistic Damage Tolerance Analysis of Aircraft Engine Components

Abstract

Interfaces between manufacturing process simulation software (DEFORM) and probabilistic damage tolerance analysis software (DARWIN) have been developed for bulk residual stresses and average grain size. These interfaces permit full-field results from manufacturing process simulations to be incorporated in predictions of fracture life and reliability. Approaches were presented for modeling the effects of location-specific bulk residual stress and average grain size on crack growth behavior. The interface and the proposed approaches were implemented in prototype software and used to perform demonstration examples for an idealized engine disk. The exercise demonstrates the practical potential for Integrated Computational Materials Engineering (ICME) that directly addresses component integrity.