Simulation and Validation of Forming, Milling, Welding and Heat Treatment of an Alloy 718 Component

This paper describes finite element simulations of a manufacturing process chain consisting of forming, weld preparation by milling, laser welding and stress relief heat treatment of an alloy 718 aero-engine part. The work also includes experimental validation with optical measurements of the part after each process step. Approximation and discretization errors were avoided by keeping the same mesh and constitutive model. The results show that the remaining stresses affect the subsequent manufacturing process step and therefore, simulation of the process chain is essential. The accuracy with respect to the geometry showed relatively good agreement between measurement and simulation.