Abstract
In the process of complex engineering designs or optimizations, a large number of physical experiments or numerical simulations are required to evaluate certain performance qualities before a satisfactory result can be obtained. In both cases, constructing an approximate model is often necessary to provide a reliable response as an alternative to experiments or simulations. In this paper, three types of approximation models were developed and applied in a shape design of an aerofoil forging preform tool. Their modeling techniques are presented in detail. An optimal Latin hypercube technique was employed for the design of the experiment and sampling with the expected coverage of parameter space. Finite element (FE) simulations of multistep forging processes were implemented to acquire the objective function values for evaluating the forging performance. By a parametric study, the effects of design variables on objective responses and correlations were investigated for a clear insight into their functional nature. Comprehensive analyses and comparisons between different approximate models have been carried out. Finally, an optimization design of a preform tool was successfully achieved based on a particle swarm (PSO) algorithm combined with the proposed approximate model.
Highlights
The aeroengine blade is a product which is mainly formed by a hot forging process
This study mainly focuses on the approximate accuracy when different surrogate models face a multi-objective engineering design optimization with complex nonlinearity
The high damage values totally concentrate on the two sides near the both declined comparatively. This will contribute to enhancing forming qualities and reducing h flashIn area where high effective strains exist
Summary
The aeroengine blade is a product which is mainly formed by a hot forging process. It usually possesses a complicated shape, high dimensional accuracy, and superior mechanical performance.Considering the difficulty of blade forging technology, a multistage hot forging process is necessary to make the workpiece gradually approach a desired shape. The aeroengine blade is a product which is mainly formed by a hot forging process. It usually possesses a complicated shape, high dimensional accuracy, and superior mechanical performance. Considering the difficulty of blade forging technology, a multistage hot forging process is necessary to make the workpiece gradually approach a desired shape. An appropriate preform design often plays a key role in the forging of aerofoil blades. For a period of time, much attention has been paid to the shape-design of preform or correlative tools in forging optimizations. Substantial progress has been made in the area of multi-objective optimization for preform design through combinations with optimal theories or mathematical programming methods
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