Sustainable manufacturing of aero engine components using shear spinning in alloy 718

Important results from the project

Within the project, a demonstrator geometry of commercial interest to the Aero engine industry has been successfully manufactured. The manufacturing process has been demonstrated, which is the basis for further dialogue about possibilities for future production. Geometry, materials, tolerance requirements and proposals for process layouts and parameters for shear spinning and post-processing were defined early in the project. FE modeling has been carried out. The sustainability gains are assessed as very large by GKN.

Expected long term effects

Shear spinned parts show great potential for the manufacturing method. Sustainability gains with respect to reduced material and energy consumption are considered to be large. Modeling and simulation where anisotropic properties and a damage and fracture model have been carried out. Certain simplifications and assumptions have been made, e.g. around tool movements and number of process steps. The results are promising even if further model development is required. Some ovality of pressure-turned parts presents a challenge for subsequent processing.

Approach and implementation

The project implementation with experimental tests and FE modeling has been successful. Great experience of participating SMEs has contributed to successful results, while understanding of challenges in the current material and the need for systematic work has increased. Planned workshop with the Aero engine engine industry can create possibilities for further work and projects aiming for commercial assignments.