Numerical Simulation For Forging Process Of Some Aeronautic Workpiece And A Gas Turbine Compressor Blade

The metal plastic forming is a complex process, which is affected by material properties, friction condition, technological conditions, structure of dies, and the equipments. So far, the design of technology and dies mainly depends on the engineering experience and involves repeated trial-and-errors. This will result in the long research period and high cost, and the quality of products also can't be guaranteed absolutely. With the development of computer technique and numerical methods, the FEM numerical calculation method has been widely used to simulate the metal plastic forming process, through which both the deformation and the distribution of several field variables could be obtained. All of these could be very helpful to predict occurrence of forging defects, to reduce the cost and to guarantee the quality of products.The titanium alloys workpiece is applied in aeronautic industry, which has large deformation in head during forging process. As the deformation of workpiece is not symmetrical, if the technical scheme is not appropriate, some forging defects may occur. In order to solve the problems appearing in production, a 3D coupled thermo-mechanical finite element model for forging process of TC4 alloy workpiece has been established, and the software DEFORM is used to simulate the forging process based on the rigid-viscoplastic finite element method. The deformation of workpiece and some thermo-mechanical field variables such as temperature > stress/strain and damage value are obtained, through which the cause of forging defects is analyzed, and the size of dies has been optimized. The simulation results agree well with the industrial trials.The material of gas turbine compressor blade is a new kind of steel. In this paper, the forging process of the gas turbine compressor blade is simulated, using the coupled thermo-mechanical finite element method. As a result, the metal flow pattern during forging process is analyzed and distributions of some thermo-mechanical field variables such as temperature, stress and strain are obtained, through which the forming laws during forging process are revealed. Considering the thermal plasticity curve, some significant technical parameters such as the stroke of pre-forging have been obtained, and this study could provide good reference to institute technology of forging process.