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Precision Forging of
Aerofoil blades
Problem Statement
Precision Forging
The final product from a precision forging
needs little or no final machining. Cost
savings are gained from the use of less
material, and thus less scrap, the overall
decrease in energy used, and the reduction
or elimination of machining.
It was developed to minimize cost and
waste associated with post-forging
operations
Billet accuracy
High accuracy in size and shape of billet are crucial
for precision forging process accomplishment.
The initial billet dimensions must be chosen so that
the total volume weight of the billet will be the same
as that of the final product to be formed.
Variation of the volume (mass) of the billet directly
affects the precision of final forged part.
Too small volume of billet causes underfiling the die
cavity as too large billet volume lead to the overload
of the tool set and its damage.
Typically allowed volume variations of billet are
between 0.5 and 1% [2].
Further, in order to obtain good surface finish on
forgings, good surfaces are required on the billets.
Preform
Precision forging of cylindrical and axisymmetrical
parts is normally realized in single operation.
However, for more complex shapes of forging part one
or more preforming operations have to be employed.
When designing manufacturing process often there
are several ways that forging can be made.
The number of perform stages and the design of the
preform directly influence the accuracy, and cost of
final part, tool life etc [3].
For precision forging the best sequence would be one
in which minimum wears occurs in the finish die.
Also, properly designed preforms can bring forging
loads to be reduced, eliminate flow faults, cavity
interfiling and to minimize the billet stock.
Tooling
The toolings for precision forging have to fulfill two
basic requirements: to be manufactured with high
accuracy and to ensure minimal dimensional changing
during manufacturing (forging) process.
Precision forging requires a precision tool set. Any
deviation from the prescribed values in the tool
geometry may cause systematic errors on workpiece.
Process of the precision forging requires exact
guidance as well as reliable closing of the die.
These factors are crucial for the proper function of the
precision forging tool set and achievement of desired
accuracy of forging.
If dies are closed by additional closing elements, the
level of closing pressure has to be higher from the
maximum value of normal pressure inside the die.
To provide the adequate closing pressure, springs are
Temperature
It can be said that from all process variables forging
temperature and thermal occurrences during the
process are most complex and most important.
In particular it is important for dies with very narrow
tolerances and small gaps between moving elements
being any deviation of the die temperature causes
thermal expansion or shrinking of the tool elements.
It can led to significant dimensional changes of
forgings and tool malfunction.
Further, forging temperature is directly responsible
for the thermal shrinking of the forging parts,
microstructure of the final components, the flow
stress, the material formability etc. and consequently
influences their quality and accuracy.
Lubrication
Lubrication during forging is important because it
reduce friction which decrease load and die wear,
and at the same time enables better filling of the die
cavity.
The lubricant also cools the die surfaces and keeps
the die temperature rather steady during forming
process.
It could help stability of the forming process and
better part accuracy to be achieved.
Lubrication system should be chosen on the way to
be relatively insensible to temperature and pressure.
In order to maximize effects, lubricant should be
applied uniformly and persistently throughout entire
forging process.
Superplasticity
Superplasticityis a state in whichsolid
crystallinematerial is deformed well beyond its
usual breaking point, usually over about 200%
during tensile deformation. Such a state is usually
achieved at highhomologous temperature.
Requirements for it being superplastic include a
fine grain size (less than approximately 20
micrometres) and a fine dispersion of thermally
stable particles, which act to pin the grain
boundaries and maintain the fine grain structure
at the high temperatures and existence of two
phases required for superplastic deformation [4].
Investment Casting
method
1. Wax is poured into the metal mould of the blade.
2. The wax shape is taken out and dipped in ceramic
slurry so that a ceramic coating of approximately
0.25 inch is formed on it.
3. Then, it is heated, so that the wax gets melted and
ceramic is hardened.
4. Molten metal is poured in the cavity formed due to
previously melted wax.
5. The blade is then kept in computer controlled ovens for
directional solidifying process.
6. Finally, the blade is machined to required shape and then
finishing operations are done to get desired dimensional
accuracy.
To Casting
Stronger
Defects refined
in preworking.
More reliable,
less costly
Better
response to
heat treatment
What is Sustainable
manufacturing?
Sustainable
Spheres of Sustainability.
Sustainable manufacturing
through precision forging
It is evident that the material wastage is
reduced (as high as 60%) and the cost related
to machining is also reduced.
Additional benefits include reductions in the
energy and greenhouse gas emissions
associated with production, transportation,
and recycling of wasted metal.
Such reductions would impact material
sustainability and availability for high-tech
manufacturing, and provide a competitive
advantage for manufacturers.
Super alloys
1.
2.
3.
4.
Temperature control
There is important need to control forging
temperature because if one exceeds the beta
transition temperature there is a danger of the
microstructure of the alloy changing over to the beta
phase.
In order to avoid forging in beta temperature range,
there is the need to restrict the maximum forging
temperature to 50 degree Celsius lesser than the beta
transition temperature [6].
However forging pressure increases dramatically with
decrease in forging temperature.
Owing to these conflicting demands the following
temperature range available to forge narrows down
considerably.
Difficulties in precision
forging
Short life of forming tools (Dies and punches)
The life-span of the tools depends on the forging
temperature and pressure, tools material, the
shape of the preform and that of the slug, etc.
The low durability of the tools lowers the quality
of the forgings.
The most common forging defect due to low tool
durability are, i.e. shorts, laps, burrs, bends,
cracks, micro- and macro-fractures and so on.
This, in turn, affects the functionality of the final
product made from the forging.
Die
wear
In precision forging it is very important to reduce die wear.
Die wear is factor that not only affects the accuracy of
forged parts, but also the cost of the forging process.
Namely, about 70% of die changes have to be done due to
die wear because they cannot keep the desired tolerances
[7].
Tight tolerances of precise forgings additionally reduce die
life that could increase expenses of forging process
drastically.
In that sense is it of great importance to improve die life.
In case of hot and warm precision forging die life and wear
occurrence depend mostly on forging temperature.
Lower forging temperature impacts very positive to die life.
Also it reduce the formation of scale which is second major
contributor to poor die life.
Isothermal Forging
1.
2.
3.
4.
References
Akiyasha moritu et. al. Near Net Shape Forging of Titanium Alloy
Turbine Blade-ISIJ International, Vol. 31;827-833 (2011).
Jan schinzak et. al. The forging process of Aircraft engine turbine
blades-Metallurgy and foundary engineering;36;712-723(2010)
Aerospace manufacturing technology book; pg 52-64.
Bariani P.F. et. al. Integrating physical and numerical simulation
techniques to design the hot forging process of stainless steel
turbine blades, International Journal of Machine Tools &
Manufacture, 44, 2004, pp. 945951.
Z. GRONOSTAJSKI and M. HAWRYLUK The main aspects of precision
forging-ARCHIVES OF CIVIL AND MECHANICAL ENGINEERING;8; 3953
Wagner R. H., Chenot J.L.: Fundamentals of Metal Forming, Wiley,
2006
Osakada K, Nakamura T.: Research and development of precision
forging in Japan. Proceeding of 8th ITCP, Verona, 2005.
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