Flash Gap Optimization in Precision Blade Forging

Abstract

The main process for manufacturing of compressor blade made of titanium alloys is forging. In the precision forging, airfoil dimensions are made to the net shape and formation of a flash around the forging ensures the complete die filling. Some factors such as flash gap dimensions affect the accuracy of the forged blade. The elastic die deflection during the forging results in airfoil thickness error. In this paper, effects of flash gap dimensions and forging parameters on elastic die deflection are studied by an experimentally verified finite element method (FEM) model. These effects are analyzed by the response surface method (RSM). The results show that by selection of appropriate flash gap dimensions as well as the process temperature and die speed, acceptable forged blade dimensions can be achieved.  Index Terms-blade forging, elastic die deflection, flash gap dimensions, precision forging

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