| Cone-walled parts are important connecting and transmission components for aircraft engines,usually connected to the main shaft in the middle and connected to the turbine disk on the outside.They are used in high temperature and high pressure environment for a long time,so their performance requirements are strict.Due to the shape of the tapered thin wal,many problems are easily caused during forging production,such as low material utilization and uneven deformation,which leads to unsatisfac tor y performance.Preforming die is often designed by experience and simulation,which leads to low efficiency.In view of the above problems,in order to ensure that the parts are filled completely,the performance is qualified,and the utilization ratio of the materials is reduced,the shape characteristics of these parts are analyzed and a more reasonable forging process is designed.At the same time,in order to solve the problem of design and optimization of pre-formed molds,this paper proposes a pre-forming mold optimiza t io n method based on multi-disciplinary software co-simulation.Based on simulation and production test,the following research work was carried out in this paper:(1)Taking the cone wall forgings of aero-engine as the research object,the difficulties and control points in the production of cone-shaped thin-walled forgings by traditional forging technology are analyzed,and the forging process of cone-wall forgings is designed and improved.The results show that,for wall thickness uniform tapered wall forgings,the flow of the material should be controlled by optimizing the height of the cake to avoid the occurrence of folding defects;for cone wall forgings with large wall thickness differences should be pre-forged to rationally separate materials,improve material utilization and control forging deformation uniformity.(2)The pre-forming die intelligent optimization algorithm with genetic algorithm as the optimization model was designed,combined with parametric modeling and finite element simulation software.In order to achieve automatic modeling and automatic simulation,parametric modeling and finite element simulation control programs are written.The genetic algorithm is used to optimize the shape parameters of the preformed mold and the mold distance in the pre-forging process to improve the optimiza t io n efficiency.(3)Taking the turbine rotor support cone wall as the research object,the rationalit y of the improved forging process and the effectiveness of the intelligent optimiza t io n algorithm for the pre-forging die were verified by the production test of the turbine rotor supporting the cone wall.(4)The turbine rotor support cone forging was produced by 800 MN hydraulic press.Take 14 positions along the contour of the part for high-strength tissue inspection,and test the mechanical properties at the corresponding position inside the part.The test results show that the forgings all meet the standard requirements,which indicates that the forging forming process and the pre-forming die intelligent optimization algorithm have strong practicability.The original forging process and forging test results of the turbine rotor supporting cone wall forgings are analyzed,and the forging process is added to the pre-forging process.Redesign the shape and positioning of the forging according to its shape characteristics to improve material utilization and forging stability.The intelli ge nt optimization algorithm is used to optimize the turbine rotor support cone wall preforming die.The experimental production results show that the improved process is reasonable and the intelligent optimization algorithm is effective. |
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