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| 3D Die Shape Optimization Technology for Net-Shape Forging of Aerofoil Blade |
| SHAO Yong-1, 2 , LU Bin-1, Hengan Ou3, CHEN Jun-1, GUO Ping-Yi-2 |
| （1. National Die and Mold CAD Engineering Research Center, Shanghai Jiaotong University, Shanghai 200030, China； 2. Jiangsu Provincial Key Laboratory of Advanced Welding Technology, Jiangsu University of Science and Technology, Zhenjiang 212003, Jiangsu, China； 3. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham, Nottingham NG7 2RD, UK） |
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Abstract A precise simulation for net-shape forging process of aerofoil blade including flash trimming operation was investigated and a direct surface compensation method for 3D optimization design of die shapes was proposed in terms of dimensional and shape tolerances of aerofoil cross-sections emergence during forging process.Quantitative representations of aerofoil forging tolerances were established to provide a correlation between conventional dimensional and shape specifications in forging production and those quantified in FE simulation. A new algorithm employing variable weighting factors to minimize the total forging tolerances in forging optimization computations was proposed to calculate compensation quantities of die surface nodes. A surface approximation using a B-spline surface was also developed to ensure improved die surface quality for die shape representation and design. For a Ni-alloy blade test case, substantial reduction in dimensional and shape tolerances was achieved using the developed die shape optimization system.
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Received: 28 February 2012
Published: 30 October 2012
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