3D die shape optimisation for net-shape forging of aerofoil blades

Lü, Bin; Ou, Hengan; Armstrong, Cecil; Rennie, Allan

doi:10.1016/j.matdes.2008.10.007

Cited by 56 publications

(24 citation statements)

References 17 publications

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“…As can be seen in the table, the thickness and overall forging errors show strong correlation with all process parameters including friction coefficient, initial temperature of the workpiece, and die stroke, whereas the deviation error shows weak correlation with the process parameters. This result is consistent with the observation drawn in references [13] and [14] that the thickness error is largely affected in the forging step while the deviation error is mainly resulted from material springback and thermal distortion in the unloading and cooling steps. Concerning the effect of the process parameters on the overall forging error, it can be found that both the die stroke and the initial temperature of the workpiece have a bigger effect on the overall forging error than the friction coefficient.…”

Section: Stochastic Characterizationsupporting

confidence: 93%

“…1. To directly correlate FE simulation results with CMM measurement data in production, the forging errors can be further quantified as thickness and deviation errors using the following equations [14] (1a) only defines a half of the thickness error as this is a convenient way to equally split the total thickness error to the top and bottom halves of the aerofoil sections for easy calculation of the surface discrepancies between the actual and nominal aerofoil surfaces. This allows easy quantification of aerofoil surface deviations and die shape modification for reduced forging errors.…”

Section: Quantification Of Blade Forging Errors: Thickness and Deviationmentioning

confidence: 99%

“…Through an iterative procedure, a weighting factor between 0.6 and 1.0 produces fast die shape optimization convergence for 2D aerofoil forging applications. However, in 3D blade forging simulation, it was found out that die elastic deformation in forging and thermal distortion in cooling, as two most important factors, exhibit quite differently to the final dimensional and shape accuracy of hot forged aerofoil blades [14]. In particular, the results show that die-elasticity has a bigger effect on the thickness error (as given in equation (1a)), whereas thermal distortion is more influential to the deviation error (as given in equation (1b)) of forged blades.…”

Section: Minimization Of Mean (δ)mentioning

confidence: 99%

“…In the forging die design optimization, Zhao et al [10] developed an optimization method for preform shape design using a piecewise cubic B-spline function for die shape definition and a sensitivity-based optimization problem using rigid-plastic FE formulation. Ou and Balendra [11], Ou and Armstrong [12], Ou et al [13], and Lu et al [14] developed a direct die shape compensation approach to achieve net-shape forging of 2D and 3D aerofoil blades for aero-engine applications. In this method, overall aerofoil errors were defined as the thickness and deviation errors and used as the objective function.…”

Section: Introductionmentioning

confidence: 99%

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Stochastic finite-element modelling and optimization for net-shape forging of three-dimensional aero-engine blades

Lü

2011

Proceedings of the Institution of Mechanical Engineers, Part L:

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Abstract:The stochastic nature of the forging process is a key influencing factor for achievable dimensional and shape accuracy of forged aerofoil blades for aero-engine applications. In this article, a finite-element-based stochastic modelling and optimization method is presented for net-shape forging of three-dimensional (3D) aerofoil blades. A combined Monte Carlo simulation and response surface method as well as the first-order second-moment reliability method are developed to quantify the stochastic characteristics of forging errors due to uncertainties of process parameters and forging conditions. A two-step optimization approach is presented to minimize systematic errors using a direct compensation method and to reduce random variations through a variance control procedure. A 3D blade forging case study is presented to evaluate the stochastic characteristics of the dimensional errors of forged aerofoil blades in comparison with measurement data and to demonstrate much improved forging accuracy using the proposed stochastic optimization method. The results from the case study also suggest that the stochasticbased optimization method may be easily applied to other metal-forming processes.

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Section: Stochastic Characterizationsupporting

confidence: 93%

Section: Quantification Of Blade Forging Errors: Thickness and Deviationmentioning

confidence: 99%

Section: Minimization Of Mean (δ)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Stochastic finite-element modelling and optimization for net-shape forging of three-dimensional aero-engine blades

Lü

2011

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…Os métodos numéricos mostram com bastante exatidão valores de deformações equivalentes e tensões nas direções principais em regiões específicas [9].…”

Section: Introductionunclassified

Comportamento De Eixo Vazado Durante O Forjamento Em Matriz Aberta Através Da Simulação Numérica E Através De Experimento Físico

Corrêa¹,

Schaeffer²

2017

Tecnologia Em Metalurgia Materiais E Mineração

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ResumoForjamento em matriz aberta é um processo de forjamento largamente empregado para produção de eixos de grande porte como, por exemplo, eixo de transmissão para os aero geradores. Visando a redução de peso, busca-se produzir um eixo vazado que atenda as mesmas condições de trabalho de um eixo maciço. Durante o forjamento de eixos de grande porte, o eixo sofre compressões sucessivas gerando um campo de tensões que, através da simulação numérica, evidenciam-se as diferenças na distribuição de tensões ao longo da seção. Analisou-se o forjamento em matriz aberta de um tarugo cilíndrico vazado com o intuito de produzir um eixo vazado através de simulações computacionais pelo Método dos Elementos Finitos e, com base de experimentos físicos, constataram-se a validade da simulação numérica. Realizaram-se simulações baseado no FEM, utilizando o software Simufact.Forming 12.0, obtendo-se valores de distribuição de tensões e deformações. Observou-se que as regiões que apresentaram maiores concentrações de deformações equivalentes coincidiram com as regiões que apresentaram maiores concentrações de tensões na direção z encontradas nos resultados da simulação numérica, seguindo a tendência esperada. Através de experimentos físicos foi constatado que os valores das forças para cada recalque apresentado pelo software de simulação numérica ficaram bem próximos da realidade, validando a empregabilidade do uso da simulação numérica. Palavras-chave: Forjamento em matriz aberta; Método dos elementos finitos; Experimento físico. HOLLOW SHAFT BEHAVIOR DURING THE FORGING IN OPEN DIE THROUGH NUMERICAL SIMULATION AND THROUGH PHYSICAL EXPERIMENT AbstractOpen die forging is a forging process widely used for the production of large size axes as, for example, drive shaft for wind turbine. In order to reduce weight, it seeks to produce a hollow shaft that meets the same working conditions of a solid shaft. During the forging of large size shaft, the part undergoes successive compressions generating a field stress that show the differences in stress distribution throughout section through numerical simulation. It analyzed the open die forging of a hollow cylindrical billet in order to produce a hollow shaft through computer simulation by the finite element method and by physical experiments verified the validity of the numerical simulation. Simulations were performed based on FEM, using the software Simufact.Forming 12.0, getting the stress and strain distribution values. It observed that the regions that showed greater concentrations equivalent strain coincided with the regions that showed greater stress concentrations in the z direction found in the numerical simulation results following the expected trend. Through physical experiments it was verified that the values of forces for each upset presented by numerical simulation software were very close to reality, validating the employability of the use of numerical simulation.

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Die shape optimisation for net-shape accuracy in metal forming using direct search and localised response surface methods

Lü

Long

2011

Struct Multidisc Optim

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3D die shape optimisation for net-shape forging of aerofoil blades

Cited by 56 publications

References 17 publications

Stochastic finite-element modelling and optimization for net-shape forging of three-dimensional aero-engine blades

Stochastic finite-element modelling and optimization for net-shape forging of three-dimensional aero-engine blades

Comportamento De Eixo Vazado Durante O Forjamento Em Matriz Aberta Através Da Simulação Numérica E Através De Experimento Físico

Die shape optimisation for net-shape accuracy in metal forming using direct search and localised response surface methods

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