3D Die Shape Optimisation for Net-Shape Forging of Aeroengine Compressor Blades

由于严格的工艺成本和质量要求，特别是尺寸和形状规格，锻造航空发动机部件是具有挑战性的。目前的锻造设计在很大程度上依赖于设计者的知识和迭代锻造试验。即使在常规生产中，也经常需要大量的锻后修正，这会导致生产时间增加和可能的报废。该项目的目的是开发一种用于航空发动机叶片零件净锻造的新型三维模具形状优化系统。该系统的独特之处在于：一种新颖的计算公式，可以快速量化锻造叶片的尺寸和形状误差；一种稳健的优化方法，可以利用通用的工艺模拟和优化技术，高效地为锻造设计得出优化的模具形状；以及一个数值模拟框架和稳健的设计功能，可以将锻造设计和制造完全集成。这项工作将通过与工业合作伙伴劳斯莱斯公司合作进行的锻造试验和检查来验证。这样的锻造优化系统将使工业伙伴能够提高锻造设计和生产效率。这将增强英国航空发动机行业的竞争地位，并对汽车行业等其他行业产生立竿见影的影响。使用过程模拟来进行过程优化和6西格玛质量增强所需的数值实验将具有非常广泛的适用性。

Forging aeroengine components is challenging due to the stringent process cost and quality requirements and especially the dimensional and shape specifications. Current forging design is very much dependent upon the designer's knowledge and iterative forging trials. Even in routine production, considerable post-forging corrections are often required, which causes increased production time and possible scrap. The aim of the project is to develop a novel 3D die shape optimisation system for net-shape forging of aeroengine blade components. The unique features of this system are a novel computational formulation to quickly quantify dimensional and shape errors of forged blades, a robust optimisation method to efficiently derive optimised die shapes for forging design utilising generic process simulation and optimisation techniques, and a framework of numerical simulation and robust design functionalities to fully integrate forging design and manufacturing. The work will be validated by forging trials and inspections conducted in collaboration with the industrial partner, Rolls-Royce plc. Such a forging optimisation system will enable the industrial partner to improve forging design and production efficiency. It would enhance the competitive position of the UK aeroengine industry and have immediate impact in other sectors such as automotive industry. The use of process simulation to conduct numerically the experiments required for process optimisation and 6-sigma quality enhancement would have very wide applicability.