Thermal-mechanical Coupled And Dynamic Recrystallization Numerical Simulation For Rotor Blade Precision Forging Process

Blade is one of the most important parts in engines, which always works in thecondition of high temperature and high pressure and bears a variety of complex stress.In order to get good quality of blade in appearance and reasonable internalorganizational structure，blade forming process has been controlled. Based on theGH4169rotor blade as the research object, the forming process has been researched bycoupled thermo-mechanical method. The research result has some theoreticalsignificance. The main contents of this paper have been listed as follows:(1)Based on the blade traditional blocking(bar-extrusion and heading) process, thenew blocking process(extrusion blocking)has been achieved; according to the geometricmodel of finish-forging piece, all parts of traditional blocking and new blocking pieceshave been designed respectively, two sets moulds of blocking pieces have beenestablished by the three dimensional modeling software Pro/E, in order to improve themould design, moulds have been debugged by finite element software continuously.(2)The two sets of blade blocking process have been simulated with different processparameters by the finite element software DEFORM-3D. The simulated result hasshown as follows: the temperature of new blocking piece increases with the increasingbeginning temperature and friction factor, the equivalent strain field of head section ofnew blocking piece is sensitive to deformation speed; In the traditional blocking process,the temperature of bar-extrusion piece and heading piece increase and equivalent stressdecreases with increasing beginning temperature; two sets of blade blocking processparameters have been optimized as follows: the beginning temperature1020℃, frictionfactor0.2, deformation speed80mm/s.(3)Using the tracking points function of DEFROM-3D, the finish forging of the newprocess has been analyzed, and the stroke-load curve equation has been obtained byfitting Boltzmann function.(4)The simulated research result of two sets of blocking process has shown as follows:deformation-heat and friction-heat are major factors for the temperature field of two setsof blocking process，and grain degree of blocking piece has been controlled by deformation degree; the value of equivalent stress and equivalent stain of new processblocking piece is greater than traditional one, but the refined degree and uniformitydegree is better than traditional one.