Skip to main content
SpringerLink
Log in

Topology-based preform design optimization for blade forging

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Preform design plays a significant role in forging design especially for parts with complex shapes. Conventional preform design approaches include trial-and-error approach, electric field method, and shape optimization-based approaches. In this paper, by introducing the structural design optimization concept, a 3D topological preform design optimization method has been developed. In this method, a new criterion for element elimination and addition is proposed and employed for plastic deformation problems in blade forging. Based on the finite element (FE) simulation combined with optimization, the optimized preforms with and without equal cross-section constraint can be obtained. Using the optimized preform, physical experiment on forging of a blade has been implemented to validate the optimization result. Other preform-related issues, such as the feasible approaches for preparation of optimized preforms, are also discussed in detail. The result suggested that the optimized preforms could improve the deformation uniformity during forging processes with better die-filling rate and reduced waste of raw materials.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Ou H, Balendra R (1998) Die-elasticity for precision forging of aerofoil sections using finite element simulation. J Mater Process Technol 76(1–3):56–61

    Article  Google Scholar 

  2. Ou H, Armstrong CG (2006) Evaluating the effect of press and die elasticity in forging of aerofoil sections using finite element simulation. Finite Elem Anal Des 42(10):856–867

    Article  Google Scholar 

  3. Lu X, Balendra R (2001) Temperature-related errors on aerofoil section of turbine blade. J Mater Process Technol 115(2):240–244

    Article  Google Scholar 

  4. Bruschi S, Ghiotti A (2008) Distortions induced in turbine blades by hot forging and cooling. Int J Mach Tools Manuf 48(7–8):761–767

    Article  Google Scholar 

  5. Ou H, Armstrong CG, Price MA (2003) Die shape optimisation in forging of aerofoil sections. J Mater Process Technol 132(1–3):21–27

    Article  Google Scholar 

  6. Rosochowski A (2001) Die compensation procedure to negate die deflection and component springback. J Mater Process Technol 115(2):187–191

    Article  Google Scholar 

  7. Lu B, Ou H, Armstrong CG, Rennie A (2009) 3D die shape optimisation for net-shape forging of aerofoil blades. Mater Des 30(7):2490–2500

    Article  Google Scholar 

  8. Ou H, Wang P, Lu B, Long H (2012) Finite element modelling and optimisation of net-shape metal forming processes with uncertainties. Comput Struct 90–91:13–27

    Article  Google Scholar 

  9. Ou H, Balendra R. (1998) Preform design for forging of aerofoil sections using FE simulation. Journal of Materials Processing Technology 80-81(144–148

  10. Lapovok R (1998) Improvement of die life by minimisation of damage accumulation and optimisation of preform design. J Mater Process Technol 80–81:608–612

    Article  Google Scholar 

  11. Zhan M, Liu Y, Yang H (2002) Influence of the shape and position of the preform in the precision forging of a compressor blade. J Mater Process Technol 120(1–3):80–83

    Article  Google Scholar 

  12. Lv C, Zhang L, Mu Z, Tai Q, Zheng Q (2008) 3D FEM simulation of the multi-stage forging process of a gas turbine compressor blade. J Mater Process Technol 198(1–3):463–470

    Article  Google Scholar 

  13. Alimirzaloo V, Biglari FR, Sadeghi MH. (2011) Numerical and experimental investigation of preform design for hot forging of an aerofoil blade. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

  14. Park JJ, Rebelo N, Kobayashi S (1983) A new approach to preform design in metal forming with the finite element method. Int J Mach Tool Des Res 23(1):71–79

    Article  Google Scholar 

  15. Wang Z, Xue K, Liu Y (1997) Backward UBET simulation of the forging of a blade. J Mater Process Technol 65(1–3):18–21

    Article  Google Scholar 

  16. Gao T, Yang H, Y-l L (2006) Backward tracing simulation of precision forging process for blade based on 3D FEM. Trans Nonferrous Metals Soc China 16(2):639–644

    Article  Google Scholar 

  17. Alimirzaloo V, Sadeghi MH, Biglari FR (2012) Optimization of the forging of aerofoil blade using the finite element method and fuzzy-Pareto based genetic algorithm. J Mech Sci Technol 26(6):1801–1810

    Article  Google Scholar 

  18. Xie YM, Steven GP (1993) A simple evolutionary procedure for structural optimization. Comput Struct 49(5):885–896

    Article  Google Scholar 

  19. Querin O, Steven G, Xie Y (1998) Evolutionary structural optimization (ESO) using a bidirectional algorithm. Eng Comput 15(8):1031–1048

    Article  MATH  Google Scholar 

  20. Lu B, Ou H, Cui ZS (2011) Shape optimisation of preform design for precision close-die forging. Struct Multidiscip Optim 44(6):785–796

    Article  Google Scholar 

  21. Shao Y, Lu B, Ou H, Ren F, Chen J (2014) Evolutionary forging preform design optimization using strain-based criterion. Int J Adv Manuf Technol 71(1–4):69–80

    Article  Google Scholar 

  22. Shao Y, Lu B, Ou H, Chen J (2015) A new approach of preform design for forging of 3D blade based on evolutionary structural optimization. Struct Multidiscip Optim 51(1):199–211

    Article  Google Scholar 

  23. Rezaei Ashtiani HR, Parsa MH, Bisadi H (2012) Constitutive equations for elevated temperature flow behavior of commercial purity aluminum. Mater Sci Eng A 545:61–67

    Article  Google Scholar 

  24. Lu B, Ou H, Long H (2011) Die shape optimisation for net-shape accuracy in metal forming using direct search and localised response surface methods. Struct Multidiscip Optim 44(4):529–545

    Article  MathSciNet  MATH  Google Scholar 

  25. Wu CY, Hsu YC (2002) Optimal shape design of an extrusion–forging die using a polynomial network and a genetic algorithm. Int J Adv Manuf Technol 20(2):128–137

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. National Die and Mold CAD Engineering Research Center, Shanghai Jiao Tong University, Shanghai, 200030, China

    Y. Shao, B. Lu, D.K. Xu & J. Chen

  2. Jiangsu Provincial Key Laboratory of Advanced Welding Technology, Jiangsu University of Science and Technology, Zhenjiang, 212003, China

    Y. Shao & P.Y. Guo

  3. Research Institute of Baoshan Iron & Steel Co., Ltd., Shanghai, 201900, China

    D.K. Xu

  4. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

    H. Ou

  5. Department of Mechanical Engineering, University of Sheffield, Sheffield, S1 3JD, UK

    H. Long

Authors
  1. Y. Shao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. B. Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. D.K. Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. J. Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. H. Ou
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. H. Long
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. P.Y. Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to B. Lu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shao, Y., Lu, B., Xu, D. et al. Topology-based preform design optimization for blade forging. Int J Adv Manuf Technol 86, 1593–1605 (2016). https://doi.org/10.1007/s00170-015-8263-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-8263-z

Keywords

Search

Navigation