Numerical Simulation And Experimental Study On Partial Forming Technique Of Shaft

This subject comes from a horizontal research project of"Heading process and universal mold frame technology for blade forgings"between GM Team and Wuxi Turbine Blade Co., Ltd.Blades are widely used in large power turbines, gas turbines, aircraft engines and all kinds of power equipment. The products are widely used in electric power, aerospace, ship equipment, petrochemical and other fields.At present, the flat forging machine is widely used at home and abroad to achieve the upset head forging process. However, free forging has many problems, such as lower stock size precision, lower productivity, product quality depends on the operational level of workers, and higher cost, larger investment, needs two forming processes for the two-headed upsetting, etc.Taking into account these issues, basing on the deep research on forging of blank of the blade of aero engine and steam turbine, after analyzing the characteristics of the forming, a new technology which makes upsetting, extruding and closed die forging into one process is proposed for the local forming of the axis components in this paper. This technology has adopted the new design concept, a series of problems in the local forming of slender bar (the ratio of length to diameter larger than 2.5) were effectively solved by a mold structure of floating type. It also overcomes the defects that plastic instability, metal folding, surface cracking and so on. This paper adopts finite element numerical analog analysis technique to research the forging forming law of this kind of component and the general mould structure. A new general mould was designed for the upset head of components with different specification and different types. The blank which needs to forging at both ends and the ratio of length to diameter of it is lower than 6 can form at a time through the general mould. In general, this technology has many advantages of simpler technology, wider forming range, higher material utilization, longer service life of die, higher productivity and lower cost, especially in the partial precise deforming process of the slender blank.