Estimation of the Pressing Force in Blade Forming Application

T. Bellizzi, J. Boisvert, H. Champliaud, and T.-M. Dao (Canada)


Modelling, Finite element, simulation, hot forming, optimisation. SYMBOLS LIST iFz Vertical contact force at node i F Pressing force expT Experimental duration of the forming process simT Length of the time simulation T Temperature σ Stress ε strain ( )k T Constant of the plastic law ( )e T Constant of the plastic law ix Geometrical parameters a ib , ijc Polynomial functions coefficients tΔ Time step minL Size of the smallest elements c Propagation velocity E Young Modulus si


We develop a 3-D FE model to simulate the hot forming process for the turbine blades based on elastic-plastic theory and unilateral contact friction theory under isothermal assumption. Due to the quasi-static assumption, an explicit dynamic formulation is used with a scale mass matrix. A method is proposed to estimate from experimental data the temperature of the forming simulation. The evolution of the material properties versus the temperature is selected combining experimental results and bibliographic sources. The numerical model is validated using experimental data. A numerical analysis of the influence of blade size (thickness, width, length, depth) on the pressing force is described. Finally a fast model to estimate the required pressing force is proposed. A multi-input single-output model is used where the input are only defined by the geometrical parameters, the material and the temperature of the blade and the output is the pressing force. The model is approximated with a least square method based on FE simulation results. Comparisons are made between the fast and FE models.

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