3D FEM simulation of the multi-stage forging process of a gas turbine compressor blade

Due to the complicated three-dimensional geometry and the non-steady state contact between the workpiece and the die surface, the simulation of blade forging process performed so far has been restricted to two-dimensional plane-strain problems or simplified three-dimensional deformational cases throughout which some simplifications and assumptions are employed. This study attempts to simulate an entire forging process of a gas turbine compressor blade from a cylindrical billet to a complicated product, using 3D rigid-viscoplastic FEM. Simulation successfully predicts a complete load/time diagram and deformed configurations on the preforming stages and the following forging stage. Meanwhile, the distribution of different field-variables, such as strain and temperature, were obtained. On the basis of these results, a change of the original forging stage is recommended. The validity of simulation results was verified through comparisons with industrial trials, which were conducted on the same process parameters as those in the simulation. The simulation results may be effectively applied to other types of three-dimensional turbine blade forging processes.