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Analysis and prospects of efficient and precise forming technology for aeroengine turbine shafts

Shu Xuedao, Chen Lulu, Pater Zbigniew, Li Zixuan, Jie Xuhai, Xia Yingxiang, Zhang Song, Chen Qian, Xu Yongming, Bartnicki Jarosław

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 1

132--147

The turbine shaft is a crucial core component of aeroengines, made of difficult-to-deform high-temperature alloy materials, characterized as a long hollow stepped shaft with deep internal holes. Achieving efficient, high-performance, and precise manufacturing of turbine shafts is a cutting-edge issue urgently needing resolution in the field of aeroengine manufacturing. Currently, the forming process for turbine shafts mainly involves forging the external shape, followed by machining the outer profile and drilling the internal holes, which presents problems such as low efficiency and high material consumption. This paper analyzes the principles and characteristics of advanced forming processes for shaft components, including cross-wedge rolling (CWR), three-roll skew rolling (TRSR), and piercing and cross rolling integration (PCRWI). This paper expounds the principles and characteristics of these process forming turbine shafts, concluding that an integrated short-process flexible forming method is the future development direction for precise plastic forming of aeroengine turbine shafts. The research results have significant theoretical value and practical engineering implications for enhancing the overall manufacturing capability of aeroengines.

Investigation of Sheet-Titanium Forming with Flexible Tool - Experiment and Simulation

Adamus J., Lacki P.

Archives of Metallurgy and Materials

2012

Vol. 57, iss. 4

1247-1252

In the paper the results of investigation of sheet-titanium forming with flexible tool are presented. Titanium alloy sheets belong to a group of materials which are very hard to deform at ambient temperature. To improve sheet formability forming technology using a semi-flexible tool was implemented. Experiments were carried out on a specially designed for this purpose device. Due to the application of a rubber pad the stress state similar to triaxial compression was produced in the deformed material. Such a stress state made it possible to obtain higher material deformation without risk of fracture. The numerical simulations were used for analysing the flexible forming process. The ADINA System basing on the Finite Element Method (FEM) was applied.

W artykule zaprezentowano wyniki badań procesu tłoczenia blach tytanowych za pomocą elastycznego narzędzia. Blachy ze stopów tytanu należą do grupy materiałów trudno odkształcalnych w temperaturze otoczenia. W celu zwiększenia tłoczności zastosowano technologie tłoczenia półelastycznym narzędziem. Doświadczenia przeprowadzono na stanowisku specjalnie zaprojektowanym w tym celu. Dzięki zastosowaniu gumowej wkładki w odkształcanym materiale wytworzony został stan naprężenia podobny do trójosiowego ściskania. Taki stan naprężenia umożliwił uzyskanie większych odkształceń materiału bez ryzyka pęknięcia. Do analizy procesu tłoczenia elastycznego wykorzystano symulacje numeryczne. Zastosowano program ADINA bazujący na Metodzie Elementów Skończonych (MES).