Numerical Simulation And Analysis Of Forming Process Of Nickel Base Superalloy Blade Forging

A blade plays the role of energy conversion in aero engine. At present, the advanced aero engineblades are made by precision forging process. As the blade surface is distorted and the materials usedare difficult deformation alloy, the blade forming process is very complex. Therefore, the method ofthe coupled thermo-mechanical numerical simulation is used to research the precision forging processof blade made of superalloy GH4169in this thesis. The main contents are as follows:Through the thermal simulation compression test of nickel based superalloy GH4169under acertain condition, the true stress-true strain curves have been obtained during the hot deformation andthe influence of deformation condition temperature on flow stress has also been analyzed. theconstitutive equations in the temperature ranging from980℃1100℃and strain rate ranging from0.01to10s-1for GH4169alloy is established.Based on the finite element simulation analysis software DEFORM, the author studied the bladeprecision forging simulation method for the calculation of the forming process and solved theboundary condition processing, plastic deformation work and friction work, the temperature fieldcalculation steps, meshing key problems, which prepares for simulation.Develop the crowded bar, pre and final forging precision forging process according to the shapeof a compressor blade and design the crowded bar billet mold and final forging die.Set out a plan of different molding rate, different friction factor and different die preheatingtemperature in the crowded bar billet. Then analysis the effect of different process parameters oneffective stress field, effective strain field, temperature field and injury.Under the specific process, the blade preform and final forging process was studied by numericalsimulation analysis. The temperature field, effective stress field, effective strain field, and loadingcurves vs. stroke have been obtained, and the regularity of precision forging process of the blade witha damper platform have been revealed.Combine the analysis of simulation results with the production practice, and ultimately determinethe best process route: crowded bar, preform and finish forging. And the optimal process parameters:blank initial forging temperature is980℃, die preheating temperature is900℃, die rate is10mm/sand the friction factor is controlled at about0.1by adding glass lubricant.