Numerical Simulation of Rotary Forging Inconel 718 Superalloy Applied to Aeronautical Components
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Numerical Simulation of Rotary Forging Inconel 718 Superalloy Applied to Aeronautical Components A. Loyda, G.M. Hernández-Muñoz, L.A. Reyes-Osorio, P. Zambrano, F. Montemayor-Ibarra Universidad Autónoma de Nuevo León. Facultad de Ingeniería Mecánica y Eléctrica. Centro de Investigación e Innovación en Ingeniería Aeronáutica, Ave. Universidad S/N, Cd. Universitaria, San Nicolás de los Garza, N.L. C.P. 66451 ABSTRACT Nowadays the aeronautical industry keeps strict quality standards in its dimensional specifications, mechanical properties and microstructural characteristics. Therefore, the involved manufacturing processes require keeping high standards. The nickel based superalloys are present in many components of the jet engines, being the Inconel 718MR superalloy the most common, making up to 50% of the jet engine. This is designed to resist high temperatures, corrosion and creep. The process of rotary forging is a manufacturing process that is currently under scientific and technological development in the aeronautical industry. An Avrami model coupled with a commercial FEM platform (DEFORMTM 3D) was developed to evaluate the average grain size, as a function of the working conditions at 980 ºC and 1000 ºC. The results provide a better understanding of the influence of temperature in the grain size evolution during the rotary forging process, compared with previous reports. INTRODUCTION Inconel 718MR is the most commercially important nickel-based superalloy used by the aeronautical industry. It is exposed to one of the most extreme environments in the aircrafts engines [1]. This alloy is used for critical rotating parts, blades, supporting structures and pressure vessels, which have to withstand high operating temperatures and require physical and mechanical properties such as high strength, tensile ductility, low creep, fracture toughness, and resistance to crack propagation [2]. Because of their strength retention at elevated temperatures, superalloys are more difficult to forge than most metals. The forgeability varies widely depending on the type of superalloy and its exact composition [1]. Rotary forging is a metal forming process technology innovative compared with conventional forging. It can be used to reduce the forming process, obtaining higher deformation ratios without cracks in one step [3]. The incremental nature of rotary forging offers a possible alternative to conventional bulk forming processes. Parts can be rotary forged using a fraction of the force needed by conventional bulk forming processes. On some rotary forging machines, parts can be rotary forged using up to 10 times less force than that required by bulk forging techniques [4]. Aeronautical forged components face the challenges of designing and testing; hence, simulation has an important role in every process development. For that reason, the creation of a simulation model using a finite element method (FEM) is important to implement the microstructural calculation. To develop the experimental model, the deformation process with it
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