3D Rigid-Viscoplastic FEM Simulation of Forging Process of a Gas Turbine Rotor Blade
Analysis of the forging of gas turbine rotor blades is a complex operation because of the complicated three-dimensional geometry and the non-steady state contact between the workpiece and the die surface. As a result, the simulation of blade forging performed so far has been restricted to two-dimensional plane-strain problems or simplified three-dimensional deformational cases throughout which some simplifications and assumptions are employed. In this paper a three-dimensional analysis of the non-isothermal multi-stage forging process of a gas turbine rotor blade from a cylindrical billet to a complicated product is presented, using 3D rigid-viscoplastic FEM. The simulation results of the blade forging processes are summarized in terms of deformed configurations, the material flow net pattern of typical cross-sections, the distribution of different field variables such as strain and stress, and the load-stroke relationships for each operational stage, in this way the forming laws during forging process of a gas turbine rotor blade being revealed. The validity of simulation results has been verified through comparisons with forging tests, which show good agreements with numerical simulation results. The simulation results may be effectively applied to other types of three-dimensional turbine blade forging processes.
Chengyu Jiang, Geng Liu, Dinghua Zhang and Xipeng Xu
C. Lv et al., "3D Rigid-Viscoplastic FEM Simulation of Forging Process of a Gas Turbine Rotor Blade", Materials Science Forum, Vols. 532-533, pp. 733-736, 2006