Study On Die Forging Process Of Blade And It Improvement

High temperature alloy blades are important components of power machinery such as aircraft engines,industrial steam turbines,gas turbines,and compressors,playing a crucial role in energy conversion.The current production method of a certain company is"free forging+close die forging".High temperature alloys have high deformation resistance,poor flowability,and narrow forming temperature range.For high-temperature alloy blades with complex shapes,underfilling defects are prone to occur in the deep and narrow parts of the forging die cavity（45 steel with better fluidity is less likely to occur）.This article introduces the concept of"non-fit",which actively considers the appropriate non fit between the forging die chamber and the deformed metal to reduce the strain ball stress of the metal.This article attempts to improve the filling effect by setting expansion spaces in areas where underfilling is prone to occur in the final forging die.Numerical simulation experiments were conducted using Deform-3D software to explore the expansion space of three types of structures:concave,convex,and inclined.From the perspective of ensuring filling effect and reducing manufacturing difficulty,the oblique shape has the best effect,with geometric parameters of length L₁=L₂=11 mm on both sides,depth H=6 mm,and edge transition fillet R=3 mm.An analysis was also conducted on the forming load,equivalent stress,equivalent strain,metal flow pattern,forging temperature at different stages,and mold wear,resulting in a forming load of 1.96×10⁷ N for the expansion of high-temperature alloy blades,the distribution diagram of metal flow velocity at different stages and the minimum die wear at the expanding space.Setting expansion space at appropriate parts of the forging die can significantly improve the filling effect of areas prone to underfilling without increasing the forming load.