Research On Automatic Modeling And Multiscale Of Blade Rolling Forming

Blade is an important component of aero-engine,and its dimensional accuracy and microstructure directly affect the performance of aero-engine.Rolling process has the advantages of low production cost and short manufacturing cycle,which has been widely used in aeroengine blade processing.The rolling of blade is a process of obtaining the blade which meets the requirements of macro shape,size and microstructure through plastic deformation.It is difficult to reflect the multi-scale deformation behavior of material in plastic deformation by single scale numerical simulation.Based on the cross-scale method and crystal plastic finite element method,this paper establishes the multiscale finite element model of blade rolling process,explores the plastic flow and texture evolution in the forming process,and realizes the accurate prediction of the size and texture evolution in the blade rolling process,which is of great significance to the design of rolling die and the determination of process parameters.The details are as follows:(1)Development of parametric modeling program for blade rolling processIn order to solve the problem of complex modeling and repeated modeling in the process of macro numerical simulation of blade rolling,a parametric numerical modeling program for blade rolling was developed.Taking the rolling process of tenon less stator blade in a factory as the research object,according to the actual processing technology,using Python language combined with ABAQUS software for secondary development,the finite element model of blade is established,and the parameterization of pre-processing contents such as geometric modeling,mesh generation,material assignment and boundary condition application are realized.(2)Development of post treatment for blade roll formingIn order to solve the problem that the post-processing function is not perfect in the simulation,and it is unable to obtain the blade profile coordinates after roll forming,a profile coordinate query method is proposed.According to the length direction and width direction coordinates of the surface points to be queried,the node information is filtered,and the node set around the query position is obtained.The length direction and width direction coordinates of the set are used as independent variables,and the thickness direction coordinates are used as dependent variables to fit the local surface function of the query surface,and then the surface point coordinates are obtained.Compared with the measured results of the actual rolling blade in the factory,the profile coordinates are within the allowable error range,which verifies the effectiveness of the macro numerical simulation platform for blade rolling forming.(3)Establishment of crystal plastic finite element modelThe secondary development was carried out in ABAQUS to realize the establishment of crystal plastic finite element model.Firstly,the crystal plastic constitutive relation is established by ABAQUS user-defined material subroutine;Secondly,Voronoi algorithm is used to establish the geometric model of polycrystal;Finally,the Eulerian space partition method is used to generate and assign the crystal orientation,and the crystal plastic finite element model is established.Uniaxial tension was simulated by using the crystal plastic finite element model,and the mesh sensitivity and the number of grains needed to represent the volume element model were studied;The material parameters in the crystal plasticity model were determined by comparing the uniaxial tensile test data with the simulation results;By comparing the compression simulation results with the experimental results,the ability of crystal plasticity model to simulate the evolution of crystal texture is verified,and the texture evolution law in tension and compression deformation is analyzed.(4)Multiscale simulation of blade roll formingThe macro numerical simulation of blade rolling forming process was carried out.The stress,strain analysis and deformation in the rolling forming process were analyzed,and the deformation history of material in three-dimensional deformation path was extracted.Using the sub model method and the crystal plastic finite element method,the meso crystal plastic finite element model of the local region of the blade is established,and the texture evolution law of different regions and different reduction is analyzed.