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

Analysis of the forging of aerofoil blades, particularly those for aeroengi nes, is a complex operation because of the complicated three-dimensional ge ometry and the non steadystate contact between the workpiece and the die su rface. In this paper a three-dimensional analysis of the hot forging of a t itanium compressor blade, currently being made and used commercially, using the finite element method is presented and validated by the results from h ot-die forging tests. The process is modelled assuming isothermal condition s, the main interest being the mechanics of the deformation. Abaqus/Explici t 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. Pre dicted strain patterns in sections of forging, using either 2-D or 3-D anal ysis are compared. It is shown that the experimental forging load and the overall flow pattern are predicted by the analysis with good accuracy.