Finite Element Modeling of Quenching Residual Stress in GH4169 Alloy Turbine Disk Forgings

A finite element model was established to investigate the formation mechanism and evolution behavior of quenching residual stress in GH4169 alloy turbine disk forgings, and the model was validated by X-ray diffraction and hole-drilling measurements. The results show that the evolution of quenching residual stress can be divided into three stages, and the stress distribution is closely related to the temperature gradient and plastic deformation. During quenching, the stress state gradually changes from “inner compression–outer tension” to “inner tension–outer compression”. After quenching, the residual stress field is characterized by surface compressive stress and internal tensile stress, with the maximum compressive and tensile stresses reaching about −794 MPa and +720 MPa, respectively. Both equivalent stress and equivalent plastic strain show high values in the surface and core regions and low values in the transition region. Their maximum values appear at the disk surface, reaching 733.4 MPa and 6.018%, respectively. Further analysis indicates that the spatial and temporal evolution of plastic strain is strongly dependent on the temperature gradient. The incompatible plastic deformation induced by the temperature gradient is the dominant mechanism for quenching residual stress formation, while the accumulation of plastic strain directly determines the magnitude and distribution of the residual stress. The relative deviation between the simulated and measured residual stresses is about 15%, which is within the acceptable range for engineering simulation, confirming the reliability and engineering applicability of the established model.