Preform Design with Improvement of Deformation Uniformity in Blade Forging Based on Topology Optimization Method

Abstract

Abstract:

In order to design and optimize the preform, new element addition and removal criteria were proposed for improving the forging uniformity based on the evolutionary structural optimization (ESO) method. By utilizing the self-programmed code and DEFORM-2D FE software, the optimal design of the aerofoil section of the blade was implemented. Compared with the preform optimized by hydrostatic stress from the existing literature, the preform optimized by the new strategy achieves sufficient die-filling and enhances forging uniformity effectively. Besides, it has relatively simple contour and is convenient to be formed. The satisfactory preform structure is obtained finally.

Key words: blade, preform design, evolutionary structural optimization, topology optimization

CLC Number:

TG 312

SHAO Yong1,2,LU Bin1,REN Facai1,CHEN Jun1. Preform Design with Improvement of Deformation Uniformity in Blade Forging Based on Topology Optimization Method[J]. Journal of Shanghai Jiaotong University, 2014, 48(03): 399-404.

References

［1］Park J J, Rebelo N, Kobayashi S. A new approach to preform design in metal forming with the finite element method［J］. International Journal of Machine Tool Design and Research, 1983, 23(1): 7179.

［2］Gao T, Yang H, Liu Y L. Backward tracing simulation of precision forging process for blade based on 3D FEM［J］. Transactions of Nonferrous Metals Society of China, 2006, 16(Sup. 2): s639s644.

［3］Cai J, Li F G, Liu T Y. A new approach of preform design based on 3D electrostatic field simulation and geometric transformation［J］. International Journal of Advanced Manufacturing Technology, 2011, 56(58): 579588.

［4］Zhao X H, Zhao G Q, Wang G C, et al. Sensitivity analysis based multiple objective preform die

shape optimal design in metal forging［J］. Journal of Materials Science and Technology, 2006, 22(2): 273278.

［5］Guan J, Wang G C, Guo T, et al. The microstructure optimization of Hshape forgings based on preforming die design［J］. Materials Science and Engineering A, 2009, 499(12): 304308.

［6］Fourment L, Mass T, Marie S, et al. Optimization of a range of 2D and 3D bulk forming processes by a metamodel assisted evolution strategy［J］. International Journal of Material Forming, 2009, 2(Sup.1): 343346.

［7］汤禹成, 周雄辉, 陈军. 基于神经网络响应曲面的预锻模具形状优化与再设计方法［J］. 上海交通大学学报, 2007, 41(4): 624628.

TANG Yucheng, ZHOU Xionghui, CHEN Jun. The optimum preform design and redesign based on neural network response surface methodology［J］. Journal of Shanghai Jiaotong University, 2007, 41(4): 624628.

［8］邵勇, 陆彬, 陈军, 等. 体积成形预成形设计及优化方法的研究与应用［J］. 塑性工程学报, 2012, 19(6): 19.

SHAO Yong, LU Bin，CHEN Jun, et al. Research and application of bulk metal preform design and optimization methods［J］. Journal of Plasticity Engineering, 2012, 19(6): 19.

［9］Lu B, Ou H, Cui Z S. Shape optimisation of preform design for precision closedie forging［J］. Structural and Multidisciplinary Optimization, 2011, 44(6): 785796.

［10］邵勇, 陆彬, 陈军, 等. 基于渐进优化的锻造预成形优化设计研究［J］. 机械工程学报, 2012, 48(22): 6571.

SHAO Yong, LU Bin, CHEN Jun, et al. Research on optimal design of preform of forging based on

evolutionary structural optimization［J］. Journal of Mechanical Engineering, 2012, 48(22):6571.

［11］邵勇, 陆彬, 陈军, 等. 基于双向渐进结构优化的叶片锻件预成形设计［J］. 材料科学与工艺, 2012, 20(6): 108114.

SHAO Yong, LU Bin, CHEN Jun, et al. Optimal design of preform of blade forging based on Bidirectional evolutionary structural optimization［J］. Materials Science and Technology, 2012, 20(6): 108114.

［12］Lu B, Ou H, Armstrong C G, et al. 3D die shape optimisation for netshape forging of aerofoil blades［J］. Materials and Design, 2009, 30(7): 24902500.

［13］Huang X, Xie Y M. Evolutionary topology optimization of continuum structures: Methods and applications［M］. Chichester, England: John Wiley & Sons, Ltd, 2010.

[1]	CHUANG Zhenju, LI Chunzheng, LIU Shewen. Numerical Analysis of Influence of Blade Icing on Dynamic Response of Integrated Wind Turbine Structure [J]. Journal of Shanghai Jiao Tong University, 2022, 56(9): 1176-1187.
[2]	XIAO Kehua, LUO Jiahao, RAO Yu. Experiment on Wedge-Shaped Latticework Channel Cooling Applied in Aero Engine Gas Turbine Blade Trailing Edge [J]. Journal of Shanghai Jiao Tong University, 2022, 56(8): 1034-1042.
[3]	ZHOU Yi, ZHOU Liangcai, DING Jiali, GAO Jianing. Power Network Topology Optimization and Power Flow Control Based on Deep Reinforcement Learning [J]. Journal of Shanghai Jiao Tong University, 2021, 55(S2): 7-14.
[4]	DING Mao, GENG Da, ZHOU Mingdong, LAI Xinmin. Topology Optimization Strategy of Structural Strength Based on Variable Density Method [J]. Journal of Shanghai Jiao Tong University, 2021, 55(6): 764-773.
[5]	ZHENG Changlong, DING Xiaohong, SHEN Hong, ZHAO Lijuan. Dynamic Topology Optimization of Rudder Structure Based on Adaptive Growth Method [J]. Air & Space Defense, 2021, 4(2): 7-.
[6]	ZHUANG Haowan, TENG Jinfang, ZHU Mingmin, QIANG Xiaoqing. Impacts of Blades Considering Manufacturing Tolerances on Aerodynamic Performance of Compressor [J]. Journal of Shanghai Jiaotong University, 2020, 54(9): 935-942.
[7]	KOU Haixia, AN Zongwen, MA Qiang, GUO Xu. Lifetime Prediction of Wind Turbine Blade Based on Full-Scale Fatigue Testing [J]. J Shanghai Jiaotong Univ Sci, 2020, 25(6): 755-761.
[8]	CHAI Xianghai，ZHANG Zhinan，YAN Jun，LIU Chuanxin. Lightweight Design for Improving Aeroengine Fan Blade Impact Resistance Capability [J]. Journal of Shanghai Jiaotong University, 2020, 54(2): 186-192.
[9]	CEN Haitang (岑海堂), WEI Ruitao (魏瑞涛), TIAN Wenliang (田文良), HUANG Jinlei (黄金磊), NA Risu (那日苏) . Finite Element Simulation Study on Blade Coating of Wind Turbine [J]. Journal of Shanghai Jiao Tong University (Science), 2020, 25(2): 223-229.
[10]	GAO Yunkai, MA Chao, LIU Zhe, TIAN Linli. Discrete Topology Optimization of Body-in-White Welding Production Platform Based on NSGA-III [J]. Journal of Shanghai Jiao Tong University, 2020, 54(12): 1324-1334.
[11]	ZHANG Ke, WU Yadong. Blade Optimization Design for Expanding Stable Operating Range of High Bypass Ratio Fan [J]. Journal of Shanghai Jiaotong University, 2020, 54(10): 1024-1034.
[12]	YE Liyu, WANG Chao, GUO Chunyu, CHANG Xin. Strength Check Method of Blade Edge Under Concentrated Ice Load Condition [J]. Journal of Shanghai Jiaotong University, 2020, 54(1): 10-19.
[13]	YANG Deqing，QIN Haoxing. Metamaterials Design with Arbitrary Poisson’s Ratio by Functional Element Topology Optimization [J]. Journal of Shanghai Jiaotong University, 2019, 53(7): 819-829.
[14]	PAN Dinghao,WU Yadong,PENG Zhigang,OUYANG Hua,DU Zhaohui. Blade Force Characteristics and Tonal Noise Prediction of Axial Fans with Uneven-Spaced Blades [J]. Journal of Shanghai Jiaotong University, 2019, 53(6): 673-680.
[15]	PENG Zhigang,OUYANG Hua,WU Yadong,TIAN Jie. Discrete Noise Control of Automobile Cooling Fan by Combining Rotor and Stator Phase Modulation Principle [J]. Journal of Shanghai Jiaotong University, 2019, 53(4): 396-404.