Preform Design for Forging of Aerofoil Sections using FE Simulation

Abstract Finite element (FE) simulation for determining material flow, forging force history and die stress sustained during the forming of aerofoil sections is presented for different preform shapes, friction conditions and attitude of die parting-line. The results show that the above factors are essential considerations for the precision forging of aerofoil components; these factors particularly influence the material deformation in the forming process, the forging load, and the pressure contours at the contact interface. The optimal preform design for such forming processes would be with a view to minimising material removal processes, reducing the production cost and increasing the component accuracy.