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<p>The residual stresses generated during quenching of aero-engine baffle forgings significantly impact subsequent machining dimensional accuracy. To address this, structural deformation and stress simulations combining multi-load step elastic-plastic finite element analysis and element birth-death techniques were applied to analyze deformation evolution and residual stress distribution in pre-rotation and machining processes. Results show that larger forging diameters correlate with increased machining deformation. Pre-rotation technology effectively reduces residual stress in both forgings and parts while minimizing machining distortion. Enhanced residual stress release and deformation stability are achieved through optimized pre-rotation speeds. A methodology for determining optimal pre-rotation parameters was established, providing theoretical guidance for residual stress elimination in thin-walled aero-engine baffles and improving dimensional stability during machining.</p>

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Mechanism of pre-rotation regulating residual stress and machining deformation in aero-engine thin-walled baffles

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Jian Chen,
  • Xinmei Wang,
  • Lidan Fan

摘要

The residual stresses generated during quenching of aero-engine baffle forgings significantly impact subsequent machining dimensional accuracy. To address this, structural deformation and stress simulations combining multi-load step elastic-plastic finite element analysis and element birth-death techniques were applied to analyze deformation evolution and residual stress distribution in pre-rotation and machining processes. Results show that larger forging diameters correlate with increased machining deformation. Pre-rotation technology effectively reduces residual stress in both forgings and parts while minimizing machining distortion. Enhanced residual stress release and deformation stability are achieved through optimized pre-rotation speeds. A methodology for determining optimal pre-rotation parameters was established, providing theoretical guidance for residual stress elimination in thin-walled aero-engine baffles and improving dimensional stability during machining.