Abstract
This paper presents a finite element (FE) based forging simulation and optimisation approach in order to achieve net-shape forging production for aeroengine components. In the hot forging of aerofoil sections, forging errors due to die-elastic deformation, thermal distortion and press-elasticity were quantified, revealing distinctive dimensional and shape error patterns. Integrating a general purpose FE package and an optimisation code, a forging simulation and optimisation system was developed. In the forging simulation of aerofoil sections with or without press-elasticity included, the numerical results showed that a significant reduction of forging errors of forged components may be achieved.
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