Topology-based preform design optimization for blade forging

Preform design plays a significant role in forging design especially for parts with complex shapes. Conventional preform design approaches include trial-and-error approach, electric field method, and shape optimization-based approaches. In this paper, by introducing the structural design optimization concept, a 3D topological preform design optimization method has been developed. In this method, a new criterion for element elimination and addition is proposed and employed for plastic deformation problems in blade forging. Based on the finite element (FE) simulation combined with optimization, the optimized preforms with and without equal cross-section constraint can be obtained. Using the optimized preform, physical experiment on forging of a blade has been implemented to validate the optimization result. Other preform-related issues, such as the feasible approaches for preparation of optimized preforms, are also discussed in detail. The result suggested that the optimized preforms could improve the deformation uniformity during forging processes with better die-filling rate and reduced waste of raw materials.