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Effects of Process Parameters on Deformation and Temperature Uniformity of Forged Ti-6Al-4V Turbine Blade

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Abstract

This work is motivated by the frequent occurrence of macro- and microdefects within forged Ti-6Al-4V turbine blades due to the severely nonuniform strain and temperature distributions. To overcome the problem of nonuniformity during the blade forging operation, firstly, a 2D coupled thermo-mechanical finite element approach using the strain-compensated Arrhenius-type constitutive model is employed to simulate the real movements and processing conditions, and its reliability is verified experimentally. Secondly, two evaluation indexes, standard deviation of equivalent plastic strain and standard deviation of temperature, are proposed to evaluate the uniformity characteristics within the forged blade, and the effects of four process parameters including the forging velocity, friction factor, initial workpiece temperature and dwell time on the uniformity of strain and temperature distributions are carefully studied. Finally, the numerically optimized combination of process parameters is validated by the application in a practical process. The parametric study reveals that a reasonable combination of process parameters considering the flow resistance, flow localization and the effects of deformation and friction heating is crucial for the titanium alloy blade forging with uniformity. This work can provide a significant guidance for the design and optimization of blade forging processes.

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Abbreviations

A :

Material constant of Arrhenius-type constitutive model

C :

Heat capacity

D :

Diameter of preform blade

E :

Young’s modulus

h :

Convection coefficient to environment

k :

Shear yield stress

K a :

Thermal conductivity

K h :

Heat transfer coefficient between workpiece and die

m :

Friction factor

n :

Material constant of Arrhenius-type constitutive model

\(n^{\prime}\) :

Material constant of Arrhenius-type constitutive model

N r :

Ratio of forged blade cross-section area to flash cross-section area

Q :

Activation energy of hot deformation

R :

Universal gas constant

S a :

Cross-section area of final forging blade without flash

S e :

Cross-section area of flash

S d :

Forging stroke of upper die

T :

Temperature

T d :

Initial temperature of die

T e :

Temperature of environment

T w :

Initial temperature of workpiece

v :

Forging velocity

Z :

Modified Zener-Hollomon parameter

α:

Material constant of Arrhenius-type constitutive model

αt :

Thermal expansion coefficient

β:

Material constant of Arrhenius-type constitutive model

ρ:

Density

τ:

Friction stress

σ:

Flow stress

μ:

Poisson’s ratio

η:

Emissivity

DT:

Dwell time before forging

SDP:

Standard deviation of equivalent plastic strain

SDT:

Standard deviation of temperature

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Acknowledgments

The authors would like to gratefully acknowledge the financial support from the National Nature Science Foundation of China (Nos. 51675394, 51375196), the State Key Laboratory of Digital Manufacturing Equipment and Technology (No. DMETKF2016003), the grant from the High-end Talent Leading Program of Hubei Province (No. 2012-86) and the Key R&D Program of Jiangsu Province (No. BE2015005).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Shiyuan Luo & Dongsheng Qian

  2. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Shiyuan Luo, Dahu Zhu, Lin Hua & Dongsheng Qian

  3. Hubei Collaborative Innovation Center for Automotive Components Technology, Wuhan University of Technology, Wuhan, 430070, China

    Dahu Zhu & Lin Hua

  4. Blade Intelligent Manufacturing Division, HUST-Wuxi Research Institute, Wuxi, 214174, China

    Dahu Zhu & Sijie Yan

  5. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Sijie Yan

  6. Technology Center, Wuxi Turbine Blade Co., Ltd., Wuxi, 214174, China

    Fengping Yu

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  1. Shiyuan Luo
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Correspondence to Dahu Zhu.

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Luo, S., Zhu, D., Hua, L. et al. Effects of Process Parameters on Deformation and Temperature Uniformity of Forged Ti-6Al-4V Turbine Blade. J. of Materi Eng and Perform 25, 4824–4836 (2016). https://doi.org/10.1007/s11665-016-2320-0

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  • DOI: https://doi.org/10.1007/s11665-016-2320-0

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