Optimization of the geometry of a characteristic section of a complex-profile thin-walled blank of the original geometry by modeling and finite element analysis methods

Abstract

The use of superplastic forming (SPF) technology has a wide range of applications: from complex-profile body parts to multilayer spatial structures manufactured in one molding step. One of the main disadvantages of SPF is the uneven thickness of the parts obtained due to the large elongation of the material, often complicated by the design of the part. The solution to this problem is the use of modeling, which allows you to perform calculations, identify characteristic defects and optimize the workpiece in order to obtain a part with the required geometry. The paper considers issues related to the modeling of the manufacture of parts by diffusion welding (DW) with subsequent SPF and finite element analysis of the “isothermal bending” operation and subsequent SPF of the inlet protective edge of a composite gas turbine engine blade made of VT6 titanium alloy (6Al-4V Grade5). The MSC Marc software package was selected as the software package for modeling. Modeling and finite element analysis of the technological processes of isothermal bending (twisting), diffusion welding and superplastic forming of the inlet protective edge of a composite blade were performed. On the basis of the results of modeling and finite element analysis, in order to prevent violation of the internal geometry of the part in the form of rough deformation of the technological radius, it was proposed to use a round constant cross-section wire with a diameter of 3.1 mm made of stainless steel with an anti-diffusion coating applied to it. The optimal geometry of the internal cavity of the blank package and the parameters of the inserted wire were selected.