Analysis Of Precision Forging Forming Process Of Aviation Blade And Research On Collaborative Optimization Method

As a key power component of an aircraft,aero-engines play a decisive factor in the reliability,safety and overall performance of the aircraft.The blade is the core component of an aero-engine,which plays a role in energy conversion,and its quality and accuracy have an important impact on the performance of the engine.The blade has the characteristics of thin profile,variable cross-section,high forming accuracy and harsh working environment,and its design and manufacturing are difficult.At present,as the mainstream production process of blades,forging forming is widely used in aerospace,shipbuilding,general machinery and other fields.However,the traditional forging process is used to produce blades,and the flow law and dimensional accuracy of the forgings are not easy to grasp.During the forging process,it is easy to cause defects such as blade deformation,tenon cracking,and insufficient filling,and there are some problems such as low dimensional accuracy,poor quality stability,low material utilization,long forming cycle and serious mold wear.In view of the above-mentioned blade forging problems,this paper takes a certain type of aero-engine TC4 blade with complex blade profile,variable cross-section and thin wall as the research object,combined with finite element numerical simulation,theoretical analysis,data analysis,deep learning and other methods,to study its precision forging forming process and die to wear rules.The main work of this research is listed as follows:(1)According to the structural characteristics of aero-engine blades,using UG NX12.0 software to design the blade and its related molds in full three-dimensional.Considering that the blade profile has a certain torsion angle,the blade forging balance angle is designed;the burr bridge and burr groove are designed to control the metal flow in the die cavity and store the excess metal during the forging process;to ensure the formed forging,the die cavity is smoothly ejected and the die forging angle of the die is designed.In addition,a suitable margin size is designed to ensure that the dimensional accuracy of the forging meets the requirements,and the appropriate parting line is selected to finally determine the final forging die of the blade.(2)Using DEFORM finite element analysis software to establish a three-dimensional thermodynamic simulation model of TC4 blades,and the deformation temperature,deformation speed,friction boundary conditions and other parameters of the finite element model are set.Finally,the precision forging process of blade is simulated,and the influence rules of forging billet initial temperature T_w,die preheating temperature T_d,forging speed V and friction factor?on the damage,temperature field,equivalent force field,equivalent strain field and load-stroke of precision forging blade are obtained.(3)Based on the orthogonal experiment design and Archard die wear theory model,revealing the influence of different initial temperature T_w,die preheating temperature T_d,forging speed V,friction factor?on blade precision forging and die wear.The key point is:the range analysis and variance analysis are performed on the orthogonal experiment schemes and results,the orthogonal optimization process parameter combination is determined,and the validity and reliability of the orthogonal experiment design are further verified.(4)In order to predict the amount of die wear of blade precision forging forming,the orthogonal test schemes and results are used as sample data,and MATLAB software is used to establish ELM(Extreme Learning Machine),GA(Genetic Algorithm)-ELM(Extreme Learning Machine),GA(genetic algorithm)-BP(neural network)three die wear prediction models,to achieve the prediction of the wear of the precision forging blade die.The comparison after training shows that the GA(genetic algorithm)-ELM(extreme learning machine)model has higher prediction accuracy in predicting mold wear.In addition,a GA-ELM-based mold wear prediction system is developed using GUIDE functions,which can quickly and accurately achieve mold wear prediction.The work in the basic research of precision forging of TC4 alloy blade of aero-engine provides a strong theoretical support and technical support for the production of similar blades.It is of great practical significance to guide the actual production of engineering,promote the development of blade precision forging technology and improve the service life of die.