Enhanced life management methods have been developed by the Federal Aviation Administration to address the rare but significant threats posed by the manufacturing anomalies of aeroengine life-limited parts. The probabilistic damage tolerance assessment provides guidance for life management methods by requiring clarification on the effect of manufacturing on life-limited parts in the design stage. Shot peening, a typical manufacturing process, is frequently used to improve fatigue performance. In this study, a new method to correlate manufacturing with engineering that combines shot peening parameters with probabilistic surface damage tolerance assessment is proposed. Through the secondary development of the simulation’s pre-processing and post-processing, the results of residual stress are adopted as input variables of the modified probabilistic surface damage tolerance assessment to calculate the probability of failure, which is closely related to the selection of shot peening parameters. Accordingly, a new integrated model is developed for the sensitivity analysis by automating parametric modeling to improve efficiency and avoid complex workflows. Specifically, the parameters required for simulation are used as input, including the diameter, velocity, and number of shots; and the probability of failure and key parameter are used as output. Results of a sensitivity analysis case show that the probability of disk failure is reduced with the increase of shot peening parameters (number, diameter, speed), where the effect of the diameter is greater within a given range. Therefore, the method proposed in this study can efficiently and intuitively identify the key parameter in the design stage.

Aero engine compressor disks are typically life-limited parts and it is necessary to secure them through the implementation of an engineering plan and a manufacturing plan. Specifically, the engineering plan recommends the quantification of the safety of life-limited parts on the basis of probabilistic risk assessment (PRA). However, the direct correlation between plans is limited, and the effect of manufacturing parameters on the safety of life-limited parts remains to be investigated. Shot peening, as a typical method of surface manufacturing, can significantly improve the safety of life-limited parts. Therefore, a modified mathematical surface PRA method considering shot peening parameters is developed in this paper to further bridge the design and manufacturing processes. Additionally, a general database is established using the response surface method to overcome the simulation complexity. On the basis of this method and the general database, an innovative direct and efficient determination of key shot peening parameters through failure risk in the design stage is proposed. The results indicate that failure risk decreased by 3.26%, 11.31%, and 9.71%, respectively, with increasing number, diameter, and velocity of shots, with the effect of diameter being the greatest. In addition, the method improves the efficiency of determining the key parameters by 75.80%, thus satisfying the requirements of abundant and efficient iterations during the design stage.

No abstract