结合数值模拟与物理实验的叶片锻造预成形拓扑优化设计研究

Research on optimal design for preform of blade forging by topological algorithm combined with numerical simulation and physical experiment

摘要:

利用所提出的拓扑优化方法,对复杂形状叶片锻造的预成形形状进行了优化设计。详细给出了该方法在三维模式下的优化策略、优化目标、单元增删准则、几何模型处理等关键技术。以合理精简毛坯、提高模腔充填性为综合优化目标,利用自行开发的优化程序,经过十余次的优化迭代,获得了理论上的优化结果。研制了叶片锻造模具,对优化后的预成形件进行了锻造成形实验；利用激光测量设备采集了叶片锻件型面的几何数据,并与数值模拟结果进行了比对。对预成形件制备工艺的可行性进行了详细讨论。研究结果表明：基于拓扑优化方法所获得的叶片预成形设计结果较为理想。

Abstract:

Preform design of blade forging has been optimized by utilizing developed topology method in this study. The key techniques of 3D topology optimization include optimization strategy, optimization objectives, element addition and removal criterion, geometry model treatment are given in detail. To fulfill the objective of increased raw material utilizing rate and die-filling rate, a theoretical optimized preform has been obtained after a dozen optimization iterations based on the self-programmed code. Blade forging experiments are implemented to validate the formability of optimized preform form. Aerofoil section profiles extracted from actual forged blade by utilizing laser measure equipment are compared with that from the FE results. The preparation technology of optimized preform is also discussed. A satisfactory optimal result of preform design has been achieved by utilizing the topological method.