Laser Mapped Mesh Simulation for Impact Damage Residual Stress

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Solution Overview

Problem

Current numerical simulation methods for impact damage in aero-engine blades face challenges in accurately predicting internal residual stress and geometry due to errors in experimental parameters and material model failure strain, leading to inaccuracies in fatigue performance prediction.

Innovation Solution

A numerical simulation optimization method using a laser mapped solid mesh, where a finite element mesh is created by laser etching on a sample surface, and experimental measurements of impact damage are used to adjust simulation parameters until desired accuracy is achieved, incorporating notch size, residual stress, and residual strain as constraints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If numerical simulation method is used to obtain internal residual stress distribution, then measurement capability is improved, but measurement precision deteriorates due to parameter errors and material model inaccuracies

Engineering Contradiction:

Improveinternal residual stress measurement capabilityVSAvoidsimulation result accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent implements an optimization framework that uses experimental measurements of impact damage geometry and surface residual stress as feedback to iteratively adjust simulation parameters (impact parameters, material model parameters, mesh size parameters) and minimize the difference between simulation results and experimental data, thereby improving the reliability of internal residual stress prediction

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent creates a virtual copy of the physical impact damage by mapping the experimental damage geometry onto the finite element model surface, allowing the simulation to replicate the actual damage morphology and use it as a constraint to improve the accuracy of internal stress prediction

Inventive Principle:

Principle #26Copying

2Measurement precision

If exfoliation corrosion method is used to test internal residual stress, then measurement capability is improved, but time cost and material cost increase significantly

Engineering Contradiction:

Improveinternal residual stress measurement capabilityVSAvoidtesting time cost

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent uses numerical simulation to create a virtual model that copies the physical impact damage characteristics, allowing internal residual stress distribution to be obtained through computation rather than time-consuming physical testing, significantly reducing both time and material costs while maintaining measurement capability

Inventive Principle:

Principle #26Copying

3Productivity

If nominal impact parameters are used in numerical simulation, then calculation efficiency is improved, but measurement precision deteriorates due to dispersive actual impact process

Engineering Contradiction:

Improvesimulation calculation efficiencyVSAvoidimpact damage prediction accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent transforms the static nominal impact parameters into dynamic optimized parameters by implementing an optimization process that adjusts impact parameters, material model parameters, and mesh size parameters based on the difference between simulation results and experimental measurements, allowing the simulation to adapt to the actual dispersive impact process

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses experimental measurements of impact damage geometry and surface residual stress as feedback to iteratively optimize the impact parameters in the simulation, minimizing the difference between simulated and actual results, thereby improving prediction accuracy while maintaining calculation efficiency

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method improves the accuracy of numerical simulation results for impact damage geometry and internal residual stress, enabling better evaluation of impact damage tolerance and maintainability of aero-engine blades.

Implementation Method 1

mapping a finite element mesh, by using laser etching, after scaling up, onto a surface of a to-be-impacted area of a sample to form a surface solid mesh element

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20240126948A1Numerical simulation optimization method of impact damage based on laser mapped solid mesh

Publication Date: 2024.04.18 NANJING UNIV OF AERONAUTICS & ASTRONAUTICS

AI summary

A numerical simulation optimization method of impact damage based on a laser mapped solid mesh is provided, including: measuring an impact damage size, a damage profile, a surface residual strain and a surface residual stress of a solid mesh element around the damage after firing a bullet by a light gas gun to impact a mesh area of a sample and obtaining the impact damage; establishing a parameterized impact finite element model to obtain a numerically simulated impact damage size, a numerically simulated impact damage profile, a numerically simulated surface residual strain and the surface residual stress of the surface solid mesh element; and calculating relative errors between the experimental measurements and the numerically simulated impact damage size, damage profile, surface residual strain and residual stress; and determining whether the relative errors are all less than expected values until a numerical simulation result meeting the accuracy requirements are obtained.