Three-dimensional finite element modelling of forging of a titanium alloy aerofoil sectioned blade

Analysis of the forging of aerofoil blades, particularly those for aeroengines, is a complex operation because of the complicated three-dimensional geometry and the non steadystate contact between the workpiece and the die surface. In this paper a three-dimensional analysis of the hot forging of a titanium compressor blade, currently being made and used commercially, using the finite element method is presented and validated by the results from hot-die forging tests. The process is modelled assuming isothermal conditions, the main interest being the mechanics of the deformation. Abaqus/Explicit FE software has been used for process simulation in which the complicated die form, assumed rigid, has been modelled using smoothed Bezier surfaces which enable die/workpiece contact phenomena to be handled effectively. Predicted strain patterns in sections of forging, using either 2-D or 3-D analysis are compared. It is shown that the experimental forging load and the overall flow pattern are predicted by the analysis with good accuracy.