Three-Dimensional Finite Element Modelling of Forging of a Titanium Alloy Aerofoil Sectioned Blade

[+] Author and Article Information
Z. M. Hu, T. A. Dean

IRC for Materials of High Performance, School of Manufacturing and Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UK

J. W. Brooks

DONCASTERS plc, 28–30 Derby Road, Melbourne, Derbyshire, DE73 1FE, UK

J. Manuf. Sci. Eng 121(3), 366-371 (Aug 01, 1999) (6 pages) doi:10.1115/1.2832690 History: Received July 01, 1997; Revised November 01, 1998; Online January 17, 2008


Analysis of the forging of aerofoil blades, particularly those for aeroengines, is a complex operation because of the complicated three-dimensional geometry and the non steady-state contact between the workpiece and the die surface. In this paper a three-dimensional analysis of the hot forging of a titanium compressor blade, currently being made and used commercially, using the finite element method is presented and validated by the results from hot-die forging tests. The process is modelled assuming isothermal conditions, the main interest being the mechanics of the deformation. Abaqus/Explicit FE software has been used for process simulation in which the complicated die form, assumed rigid, has been modelled using smoothed Bezier surfaces which enable die/workpiece contact phenomena to be handled effectively. Predicted strain patterns in sections of forging, using either 2-D or 3-D analysis are compared. It is shown that the experimental forging load and the overall flow pattern are predicted by the analysis with good accuracy.

Copyright © 1999 by The American Society of Mechanical Engineers
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