Forging is one of the most widely used manufacturing process for making high-strength, structurally integrated, impact and creep-resistant Ti-6A1-4V compressor blades for jet engines. In addition, in modern metal forming technology, finite element analysis method and computer modeling are being extensively employed for initial evaluation and optimization of various processes, including forging. In this study, DEFORM, a rigid viscoplastic two-dimensional finite element code was used to study the effects of initial die temperature and initial ram velocity on the forging process. For a given billet, die temperature and ram velocity influence the strain rate, temperature distribution, and thus the flow stress of the material. The die temperature and the ram velocity were varied over the range 300 to 700°F and 15-25 in./sec, respectively, to estimate the maximum forging load and the total energy required to forge compressor blades. The ram velocity was assumed to vary linearly as a function of stroke. Based on the analysis, it was found that increasing the die temperature from 300 to 700°F decreases the forging loads by 19.9 percent and increases the average temperature of the workpiece by 43°F. Similarly, increasing the initial ram velocity from 15 to 25 in./sec decreases the forging loads by 25.2 percent and increases the average temperature of the workpiece by 36°F. The nodal temperature distribution is bimodal in each case. The forging energy required to forge the blades is approximately 18 kips *in./in.

Issue Section:
Gas Turbines: Manufacturing and Materials
Topics:
Blades, Compressors, Forging, Temperature, Stress, Finite element analysis, Temperature distribution, Computer simulation, Creep, Flow (Dynamics), Jet engines, Manufacturing, Metalworking, Optimization
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