Automatic preform design and optimization for aeroengine disk forgings

Abstract

To ensure a more uniform microstructure distribution of forging and improve the service performance of aeroengine disk parts, an automated preform design method is proposed for integrated preform shape design and optimization based on the NURBS curve, finite element method (FEM), and genetic algorithm (GA). Firstly, the random preform shape graph is automatically constructed by the NURBS curve design criterion. The volume and shape complexity are used as the constraints of the preform. Then the ratio of the mesh area within the set strain range to the total mesh area is used as the fitness function for the uniformity of deformation, and the genetic algorithm module is used for optimization. Finally, a large disk forging is an example of its optimal design. The results show that the deformation uniformity of the forgings is excellent, its fitness value is as high as 99.59%, and there are no problems such as folding, underfilling, and limited distribution of flash, which verifies the effectiveness of the method. In addition, the method has the advantage of strong universality, which can find the preform shape with good deformation uniformity for any shape forgings.

Research on deformation uniformity control of thin-walled conical aeroengine forgings based on GA-SVR

“…4. A substantial area of minimal deformation, with an effective strain less than 0.45, forms in regions of greater thickness due to irrational material flow, potentially causing incomplete recrystallization during the final forging process and a consequent proliferation of coarse grains [1,27]. The material flow in the final forging process is significantly influenced by the preforming shape; hence, the dimensions of the preforming dies necessitate optimization to achieve a more judicious shape.…”

“…According to the performance analyses and physicochemical test results of analogous forgings, to ensure that mechanical properties and microstructures adhere to requirements, The effective strain value of the final forging must be controlled between 0.43 and 1.02 [1]. In this study, the proportion of areas that do not achieve the effective strain requirement in the region of finished part 𝑦 1 and the average deviation between the effective strain of each element and the expected value 𝑦 2 are selected to represent deformation homogeneity, and the weighted sum of 𝑦 1 and 𝑦 2 is established as the comprehensive evaluation indices.…”

“…Certain areas, such as disc forgings hubs, journal forgings flanges, and tapered forgings centers, present formidable challenges to deformation. For these intricate forgings, effectuating deformation through a singular stage proves arduous [1][2][3][4]. Owing to the prolonged operation of forgings in extreme conditions, progress directly to the final forging stage predisposes the process to folding and filling defects, adversely impacting dimensional accuracy, and significantly diminishing mechanical properties, 1 School of Materials Science and Engineering, Chongqing University, Chongqing 400030, China * Menghan Wang cquwmh@163.com including high-temperature creep, tensile strength, and durability [2,5,6].…”

“…For these intricate forgings, effectuating deformation through a singular stage proves arduous [1][2][3][4]. Owing to the prolonged operation of forgings in extreme conditions, progress directly to the final forging stage predisposes the process to folding and filling defects, adversely impacting dimensional accuracy, and significantly diminishing mechanical properties, 1 School of Materials Science and Engineering, Chongqing University, Chongqing 400030, China * Menghan Wang cquwmh@163.com including high-temperature creep, tensile strength, and durability [2,5,6]. Customarily, a multi-stage forging process ensures the formation of highquality forgings, rendering the preforming process indispensable [7,8].…”