Preform and Process Design of Ti-6Al-4V Compressor Blade using Equipotential Lines and 3D FE Simulation

International Journal of Advanced Design and Manufacturing Technology

مقاله 5، دوره 11، شماره 1، بهار 2018، صفحه 43-50  

نوع مقاله: Original Article

نویسندگان

M. Soleimanzadeh¹؛ M.M. Fallah ²

¹Department of Mechanical Engineering, Islamic Azad University, Jasb Branch, Iran

²Department of Mechanical Engineering, Shahid Rajaee Teacher Training University, Iran

چکیده

Forging is one of the most important processes for production of titanium parts. Selection and evolution of forging parameters such as the forging preforms, part and die temperatures and strain rate are of great importance to achieve optimal process. In this work, a comprehensive study on the near net hot forging of a Ti-6Al-4V compressor blade is performed through designing several preforms and simulating the process in several die and preform temperatures. The Equipotential lines method is used for the optimal design of preforms and Johnson-Cook constitutive model is used for 3D FE simulations and the criteria for selecting the parameters was the material temperature during the process that is necessary for achieving desired properties of Ti-6Al-4V parts. According to the results, performing the isothermal forging process in increased speeds could lead to increasing the temperature over the β-transus and improper mechanical properties development. So, finding a proper die and preform temperature is necessarily accomplished in this work. According to results the appropriate temperatures for performing the process using modified 0.1v preform and ram speed of 1mm/s were 1050˚C and 450˚C for the preform and die respectively.

کلیدواژه‌ها

Equipotential lines method؛ FE Simulation؛ Hot forging of the Blade؛ preform design؛ Titanium alloy Ti-6Al-4V

مراجع

[1]     Hu, Z. M., Dean, T. A., “Aspects of Forging of Titanium Alloys and the Production of Blade Forms”, Journal of Materials Processing Technology, Vol. 111, No. 1-3, 2001, pp. 10-19.

[2]     Alimirzaloo, V., Biglari, F. R., and Sadeghi, M. H., “Numerical and Experimental Investigation of Preform Design for Hot Forging of an Aerofoil Blade”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 225, No. 7, 2011, pp. 1129-1139.

[3]     Liu, Y., Li, F., Wang, Sh., and Hu, S. J., “Preform Design of Powder Metallurgy Turbine Disks Using Equi-Potential Line Method”, Journal of Manufacturing Science and Engineering, Vol. 128, No. 3, 2006, pp. 677-682.

[4]     Cai, J., Li, F., and Liu, T., “A New Approach of Preform Design Based on 3D Electrostatic Field Simulation and Geometric Transformation”, International Journal of Advanced Manufacturing Technology, Vol. 56, No. 5-8, 2011, pp. 579-588.

[5]     Sadeghi, M. H., Baroughi, B., “Design of Preforms in Forging Process of Blade Using Equipotential Lines Method”, MSc Thesis, Tarbiat Modares University, Department of Mechanical Engineering, Tehran, Iran, 2012.

[6]     Guan, Y., Bai, X., Liu, M., Song, L., and Zhao, G., “Preform Design in Forging Process of Complex Parts by Using Quasi-Equipotential Field and Response Surface Methods”, International Journal of Advanced Manufacturing Technology, Vol. 79, No. 1-4, 2015, pp. 21-29.

[7]     Lv, Ch., Zhang, L., Mu, Zh., Tai, Q., and Zheng, Q., “3D FEM Simulation of the Multi-Stage Forging Process of a Gas Turbine Compressor Blade”, Journal of Materials Processing Technology, Vol. 198, No. 1-3, 2008, pp. 463-470.

[8]     Semiatin, S. L., Goetz, R. L., Shell, E. B., Seetharaman, V., and Ghosh, A. K., “Cavitation and Failure During Hot Forging of Ti-6Al-4V”, Metallurgical and Materials Transactions A, Vol. 30, No. 5, 1999, pp. 1411-1424.

[9]     Forming and Forging, ASM Metals Handbook, 9th ed., Vol. 14, ASM Int, Metals Park, Ohio, 1998.

[10]  Kotkunde, N., Deole, A. D., Gupta, A. K., and Singh, S. K., “Comparative Study of Constitutive Modeling for Ti–6Al–4V Alloy at Low Strain Rates and Elevated Temperatures”, Materials and Design, Vol. 55, 2014, pp. 999-1005.

[11]  Johnson, G. R., Cook, W. H., “A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures”, Proceedings of the 7th International Symposium on Ballistics, The Netherlands, The Hague, 1983, pp. 541-547.

[12]  Lee, W. Sh., Lin, Ch. F., “High-Temperature Deformation Behaviour of Ti6Al4V Alloy Evaluated by High Strain-Rate Compression Tests”, Journal of Materials Processing Technology, Vol. 75, No. 1-3, 1998, pp. 127–136.

[13]  Lesuer, D., “Experimental Investigations of Material Models for Ti-6Al-4V and 2024-T3”, A Report of Lawrence Livermore National Laboratory, 1999.

[14]  Meyer Jr, H. W., Kleponis, D. S., “Modeling the High Strain Rate Behavior of Titanium Undergoing Ballistic Impact and Penetrationˮ, International Journal of Impact Engineering, Vol. 26, No. 1-10, 2001, pp. 509-521.

[15]  Seo, S., Min, O., and Yang, H., “Constitutive Equation for Ti–6Al–4V at High Temperatures Measured Using the SHPB Technique”, International Journal of Impact Engineering, Vol. 31, No. 6, 2005, pp. 735-754.

[16]  Özel, T., Karpat, Y., “Identification of Constitutive Material Model Parameters for High-Strain Rate Metal Cutting Conditions Using Evolutionary Computational Algorithms”, Materials and Manufacturing Processes, Vol. 22, No. 5, 2007, pp. 659–667.

[17]  Kotkunde, N., Deole, A. D., Gupta, A. K., and Singh, S. K., “Comparative Study of Constitutive Modeling for Ti–6Al–4V Alloy at Low Strain Rates and Elevated Temperatures”, Materials and Design, Vol. 55, 2014, pp. 999-1005.

[18]  Bruschi, B., Poggio, S., Quadrini, F., and Tata, M. E., “Workability of Ti-6Al-4V Alloy at High Temperatures and Strain Rates”, Materials Letters, Vol. 58, No. 27-28, 2004, pp. 3622-3629.