Effects of Different Materials on Residual Stress Fields of Blade Damaged by Foreign Objects

Foreign object damage (FOD) is a common mode of failure in high-speed rotating machinery, such as aircraft engines. Therefore, research on FOD is crucial for ensuring blade integrity. FOD induces residual stress on the surface and within the blade, impacting its fatigue strength and service life. Therefore, this paper utilizes material parameters determined by existing experiments, based on the Johnson–Cook (J-C) constitutive model, to numerically simulate impact damage inflicted on specimens, compare and analyze the residual stress distribution of impact pits, and investigate the influence law of foreign object characteristics on blade residual stress. TC4 titanium alloy, 2A12 aluminum alloy, and Q235 steel were selected as foreign objects, and dynamic numerical simulations of the blade impact process were performed to explore the effects of different types of metal foreign objects. This study analyzes the influence of different materials and foreign objects on the residual stress generated by blade impact through numerical simulation, examining the distribution of residual stress in different directions. The findings indicate that the generated residual stress increases with the density of the materials. Additionally, the geometry of the impact notch is also influenced by the density difference between the impact material and the blade. The distribution of the residual stress field reveals that the maximum residual tensile stress in the blade is related to the density ratio, and the residual tensile stress in the axial and circumferential direction is relatively large. It is important to note that a significant residual tensile stress has a detrimental effect on the fatigue strength.