Residual Stress Prediction in Turbine Blade Machining Operations Using a Virtual Machining System

Part manufacturing process using machining operations is along with residual stress due to friction, chip formation and generated heat in cutting zone. The performance of produced parts in working conditions such as fatigue life, corrosion resistance and part distortion is under the influence of residual stress which should be analyzed and minimized. To produce compressor section blades of gas turbines, machining operations can be used. The process is always with complexities and challenges. However it can be analyzed and modified in virtual environments. Residual stress due to machining operations of gas turbine blades can also be analyzed in virtual environments in order to be minimized. In the present research work, application of a virtual machining system to predict residual stress in milling operations of turbine blades is presented. Finite element analysis is implemented in order to calculate residual stress as well as strain of blades in machining operations. In order to validate the research work, experimental results are compared with the finite element results obtained from the virtual machining system. The present research work can replace the costly experimental tests by predicting the residual stress in a virtual machining environment