针对航空发动机涡轮盘螺栓孔在高温高应力服役条件下的疲劳寿命问题，基于孔边应力场等效原则，提出了一种涡轮盘螺栓孔挤压强化模拟件的应力梯度匹配设计方法。通过建立热-力耦合有限元模型，系统分析了模拟件缺口深度、平行段宽度、缺口半径及厚度四个关键几何参数对应力场分布的影响规律，建立了基于参数灵敏度分析的单变量序贯优化策略。研究结果表明，增大缺口深度和平行段宽度可降低应力梯度误差，但需兼顾挤压强化刚度与试验载荷量程；缺口半径的选取需在螺栓孔半径基础上预留足够余量，以避免缺口处应力集中竞争导致的非预期断裂；厚度对应力分布及挤压强化效果的影响不显著。经缺口-螺栓孔应力集中竞争机制修正，优选出合理的模拟件构型，其应力梯度最大误差仅为7.37%，能够高保真复现真实轮盘螺栓孔的应力状态。550℃高温低周疲劳试验表明，该模拟件断裂均位于螺栓孔内壁预期考核区域，挤压强化后平均疲劳寿命较未强化试样提升203.8%。残余应力实测与仿真结果吻合良好，孔壁表面残余压应力相对误差为2.4%。本文建立的模拟件设计方法兼顾了应力场等效精度、疲劳失效模式再现及强化工艺表征三个层面的有效性，可为涡轮盘螺栓孔结构疲劳寿命评估与冷挤压强化工艺优化提供试验依据。
To address the fatigue life issue of bolt holes in aero-engine turbine disks under high-temperature and high-stress service conditions, a stress gradient matching design method for simulated specimens used in bolt hole cold expansion strengthening is proposed based on the principle of stress field equivalence around the hole. A thermo-mechanically coupled finite element model was established to systematically investigate the effects of four key geometric parameters—notch depth, parallel section width, notch radius, and thickness—on the stress field distribution of the simulated specimen, and a single-variable sequential optimization strategy based on parameter sensitivity analysis was developed. The results indicate that increasing the notch depth and parallel section width can reduce the stress gradient error, while the cold expansion strengthening stiffness and the test load range should be taken into account simultaneously; the selection of the notch radius should reserve sufficient allowance based on the bolt hole radius to avoid unexpected fracture at the notch caused by stress concentration competition; the thickness has no significant effect on stress distribution or cold expansion strengthening effectiveness. Modified by the competition mechanism analysis of notch versus bolt hole stress concentration, a reasonable simulated specimen configuration was optimized, achieving a maximum stress gradient error of merely 7.37%, which can reproduce the stress state of the actual turbine disk bolt hole with high fidelity. High-temperature low-cycle fatigue tests at 550 °C demonstrate that fractures of the simulated specimens all occur in the expected assessment zone at the inner wall of the bolt hole, and the average fatigue life after cold expansion strengthening increases by 203.8% compared with that of the unstrengthened specimens. The measured residual stresses are in good agreement with the simulation results, with a relative error of 2.4% for the surface residual compressive stress on the hole wall. The proposed specimen design method addresses the effectiveness at three levels, namely stress field equivalence accuracy, fatigue failure mode reproduction, and strengthening process characterization, which can provide experimental basis for fatigue life evaluation and cold expansion strengthening process optimization of bolt hole structures in turbine disks.
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