叶片精锻三维刚粘塑性有限元模拟系统的研究

On Developing 3D-PFS Software for Simulating Precision Forging Process of Aero-Engine Blade

叶片精锻是叶片锻造的发展趋势 ,但由于叶片形状复杂 ,所用材料难变形 ,实际生产中不得不进行反复试制 ,造成很大浪费。计算机技术的飞速发展 ,使得采用三维有限元数值模拟技术模拟叶片精锻过程成为可能。为此 ,在解决三维有限元模拟关键技术问题的基础上 ,自行开发了面向叶片精锻过程的三维刚粘塑性有限元模拟分析系统 3 D-PFS。系统的可靠性得到了以塑泥为模拟材料的物理模拟试验的验证。对不同类型叶片精锻过程的进一步模拟分析 ,结果表明 :3 D-PFS是模拟分析叶片精锻过程可靠的工具。该研究对提高叶片锻造工艺的研究水平及发展叶片精锻理论具有重要意义。

There exist commercial softwares such as DEFORM3D, FORGE3D for 3D (three dimensional) rigid visco plastic FEM (finite element method) simulation of forging process; but, in our opinion, it is still highly difficult to apply them to simulating precision forging process of aero engine blade. We have therefore developed 3D PFS (3D plastic forming simulation) software for 3D rigid visco plastic FEM simulation of precision forging process of aero engine blade. Section 1 deals with three problems encountered in the development of 3D PFS software: (1) how to deal with friction boundary condition (subsection 1.1); (2) how to remesh (subsection 1.2); (3) how to deal with dynamic boundary condition (subsection 1.3). Subsection 2.2 applies 3D PFS software to rigid visco plastic FEM simulation of precision forging process of a single tenon blade of a certain aero engine; subsection 2.3 shows that such simulation gives reliable results. Section 3 applies 3D PFS software to rigid visco plastic FEM simulation of precision forging process of a single tenon aero engine blade of more complicated shape, as a damping platform forms a part of it (Fig.4).