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

锻造航空发动机部件具有严格的工艺成本和质量要求，特别是尺寸和形状规格要求。目前的锻件设计很大程度上依赖于设计师的知识和反复的锻件试验。即使在日常生产中，也经常需要大量的锻造后修正，这导致生产时间的增加和可能的报废。该项目的目的是开发一种新的三维模具形状优化系统，用于航空发动机叶片部件的净形锻造。该系统的独特之处在于一个新的计算公式，可以快速量化锻造叶片的尺寸和形状误差；一个稳健的优化方法，可以有效地利用通用的过程模拟和优化技术，为锻造设计提供优化的模具形状；一个数值模拟框架和稳健的设计功能，可以充分整合锻造设计和制造。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。这种锻件优化系统将使工业合作伙伴能够提高锻件的设计和生产效率。这将提高英国航空发动机工业的竞争地位，并对汽车工业等其他行业产生直接影响。使用过程模拟来进行过程优化和6-sigma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.