Preform and Process Design of Ti-6Al-4V Compressor Blade using Equipotential Lines and 3D FE Simulation

Forging is one of the most important processes for production of titanium parts. Selection and evolution of forging parameters such as the forging preforms, part and die temperatures and strain rate are of great importance to achieve optimal process. In this work, a comprehensive study on the near net hot forging of a Ti-6Al-4V compressor blade is performed through designing several preforms and simulating the process in several die and preform temperatures. The Equipotential lines method is used for the optimal design of preforms and Johnson-Cook constitutive model is used for 3D FE simulations and the criteria for selecting the parameters was the material temperature during the process that is necessary for achieving desired properties of Ti-6Al-4V parts. According to the results, performing the isothermal forging process in increased speeds could lead to increasing the temperature over the β-transus and improper mechanical properties development. So, finding a proper die and preform temperature is necessarily accomplished in this work. According to results the appropriate temperatures for performing the process using modified 0.1v preform and ram speed of 1mm/s were 1050˚C and 450˚C for the preform and die respectively.