3D die shape optimisation for net-shape forging of aerofoil blades

B. Lu, H. Ou, C.G. Armstrong, A. Rennie

Research output: Contribution to journalArticlepeer-review

50 Citations (Scopus)


This paper reports on work in developing a finite element (FE) based die shape optimisation for net-shape forging of 3D aerofoil blades for aeroengine applications. Quantitative representations of aerofoil forging tolerances were established to provide a correlation between conventional dimensional and shape specifications in forging production and those quantified in FE simulation. A new direct compensation method was proposed, employing variable weighting factors to minimise the total forging tolerances in forging optimisation computations. A surface approximation using a B-spline surface was also developed to ensure improved die surface quality for die shape representation and design. For a Ni-alloy blade test case, substantial reduction in dimensional and shape tolerances was achieved using the developed die shape optimisation system.
Original languageEnglish
Pages (from-to)2490-2500
Number of pages11
JournalMaterials & Design
Issue number7
Publication statusPublished - Aug 2009

ASJC Scopus subject areas

  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science(all)


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