Evaluating the effect of press and die elasticity in forging of aerofoil sections using finite element simulation

  • Authors:

  • H. Ou;C. G. Armstrong

  • Affiliations:

  • School of Mechanical and Aerospace Engineering, Queen's University Belfast, Belfast, UK;School of Mechanical and Aerospace Engineering, Queen's University Belfast, Belfast, UK

  • Venue:
  • Finite Elements in Analysis and Design
  • Year:
  • 2006

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Abstract

This paper develops a quantitative relationship between the press and die elastic deflections and the form errors in forging of aerofoil sections using finite element (FE) simulations. A general stiffness matrix of six degrees of freedom was derived to represent the linear press load-deflection relationships, together with an equivalent clearance vector to take into account the initial non-linearity due to press geometric errors such as guideway clearances. A new matrix transformation of press deflections to forging die surface deviations was established as a function of forging force, press stiffness and spatial relationships between the forging dies and the press. FE simulations of press deflections, forging of aerofoil sections with the inclusion of press deflections and the computation of die surface deviations were carried out. The results revealed distinct patterns and magnitudes of die surface deviations due to die and press elasticity. It becomes clear that consideration of press elasticity is important if the achievable accuracy in forging of aerofoil blade components is to be enhanced.