Optimization of the Forging Process of a Gas Turbine Blade using the Finite Element Analysis and Response Surface Method
الموضوعات :
V. Alimirzaloo
1
(Department of Engineering,
University of Urmia, Iran)
F. R. Biglari
2
(Department of mechanical Engineering,
Amirkabir University of Technology, Iran)
الکلمات المفتاحية: forging, Response Surface, Finite Element, Optimization, Blade,
ملخص المقالة :
Forging of gas turbine blades needs a close control of the process parameters. These parameters require a suitable optimization method to achieve the best process conditions. This paper presents a hybrid method for the optimization of the forging process of an aerofoil blade. Forging process of the aerofoil blade was simulated using 3-dimentional finite element method. Preform shape and die parting-line angle are optimized in order to minimize the volume of the unfilled die cavity, material waste, and forging forces. The overall optimization scheme used in this research work includes a multi-objective approach that is a combination of response surface and finite element methods. The results show that the proposed optimization approach accrued to decrease the flash volume and the forging force of the aerofoil forging process. Therefore the proposed algorithm is a suitable method for the optimization of the gas turbine blade forging processes.
[1] Hu, Z.M. Dean, T. A., “Aspects of forging of titanium alloys and the production of blade forms”, J. Mat. Proc. tech. Vol. 111, 2001, pp. 10-19.
[2] Zhao, G., Wang, G. and Grandhi, R. V., “Die cavity design of near flashless forging process using FEM-based backward simulation”, Journal of Materials Processing Technology, Vol. 121, 2002, pp. 173-181.
[3] Zhao, G., Ma, X., Zhao, X. and Grandhi, R.V., () “Studies on optimization of metal forming processes using sensitivity analysis methods”, J. Mat. Proc. tech. Vol. 147, 2004, pp. 217-228.
[4] Castro, C. F., António, C. A. C. and Sousa, L. C., “Optimisation of shape and process parameters in metal forging using genetic algorithms”, J. Mat. Proc. Tech. Vol. 146, 2004, pp. 356-364.
[5] Lu, X. Balendra, R., “Tempreture related errors on aerofoil section of turbine blade”, J. Mat. Proc. Tech. Vol. 115, 2001, pp. 240-244.
[6] Lu, B., Ou, H., Armstrong, C. G. and Rennie, A., “3D die Shape optimisation for net-shape forging of aerofoil blades”, Materials and Design, doi: 10.1016/j.matdes.2008.10.007.
[7] Kang, B. S., Kim, N. and Kobayashi, S., “Computer-aided preform design in forging of an airfoil section blade”, Int. J. Mach. Tools Manufact. Vol. 30, No. 1. 1990, pp. 43-52.
[8] Tao, G., He, Y. and Yuli, L., “Influence of dynamic boundary conditions on perform design for deformation uniformity in backward simulation”, Journal of materials processing technology, Vol. 197, 2008, pp. 255-260.
[9] Tao, G., He, Y. and Le, L. Y., “Backward tracing simulation of precision forging process for blade based on 3D FEM”, trans. nonferrous met. Soc. China, Vol. 16, 2006, pp. 639-644.
[10] Deform3D. V5, manual help, 2004.
[11] Montgomery, D.C., “Design and analysis of experiments”, J. Wiley & Sons, New York, 2005.
[12] Myers, R. H. Montgomery, D. C., “Response Surface Methodology,” J. Wiley & Sons Interscience Publication, New York, 2002.
[13] Shokuhfar, A., Khalili, S. M. R., Ashenai, Ghasemi, Malekzadeh, F., K. and Raissi, S., “Analysis and optimization of smart hybrid composite plates subjected to low-velocity impact using the response surface methodology”, Thin-Walled Structures , Vol. 46, 2008, pp. 1204-1212.
[14] Amini, H., Younesi, M. and Bahramifar, N., “statistical modeling and optimization of the cadmium biosorption process in an aqueous solution using Aspergillus niger”, Colloids and Surfaces A: Physicochem. Eng. Aspects, Vol. 337, 2009, pp. 67-73.
[15] Yalcinkaya, Ö. Mirac Bayhan, G., “Modelling and optimization of average travel time for a metro line by simulation and response surface methodology”, European Journal of Operational Research, Vol. 196 2009, pp. 225-233.
[16] Kolahdoozan, M., Azimifar, F., and Rismani Yazdi, S., “Finite Element Investigation and Optimization of Tool Wear in Drilling Process of Difficult to-Cut Nickel-Based Superalloy using Response Surface Methodology”, Int J Advanced Design and Manufacturing Technology, Vol. 7, No. 2, 2014, pp. 67-76.
[17] Lin, J. F. Chou, C. C., “The response surface method and the analysis of mild oxidational wear”, Tribology International, Vol. 35, 2002, pp. 771-785.
[18] Alimirzaloo, V., Biglari, F. R., and Sadeghi, M. H., “Numerical and Experimental Investigation of Preform Design for Hot Forging of Aerofoil Blade”, J. Engineering Manufacture, Vol. 225, No. 7, 2011, pp. 1129-1139.
[19] Minitab software, V15, user’s guide, technical manual, 2008.
