Die-elasticity for precision forging of aerofoil sections using finite element simulation

Precision forging of material into turbine blades needs a clear understanding of the prevailing parameters in forging, appropriateness of preform design, process simulation and techniques for compensating component form errors due to die-elasticity. With this In mind, simulations are conducted to analyses the material flow during forging of aerofoil sections, forging force history, contact pressure distribution between die and component, and the elastic deflections of the forging dies are investigated using finite element simulation. Further, the compensation of die-elasticity is proposed by modifying die profiles in response to die deflections based on the nominal dimensions of forging dies. The minimisation of form errors of aerofoil sections due to die-elasticity is derived by iterations using FE. The results obtained enable the quantitative estimation of die-elasticity in precision forging of aerofoil sections, and the technique for compensating component-form errors to achieve net-shape forming production. (C) 1998 Elsevier Science S.A. All rights reserved.