Hollow Blade Manufacturing via Multi-Step Die Forging
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Solution Overview
Problem
The manufacturing of hollow turbomachine blades is inefficient due to high material losses and costly machining techniques, particularly when producing large blades, as existing methods reach their limits in terms of thickness variations and require excessive power, making it difficult to optimize the process without significant cost increases.
Innovation Solution
A method involving die forging in multiple successive steps, using complementary dies to forge primary parts with a low thickness-to-width ratio, allowing for the use of conventional machining techniques and reducing material loss, with the process integrated into diffusion bonding and superplastic forming for hollow blade production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional machining techniques are used to manufacture external parts with varying thickness, then the blade preform can be produced, but material losses are high and manufacturing costs increase
Solution Approach 1:
The invention changes the manufacturing parameter from conventional machining to die forging, which fundamentally alters how material is removed or shaped. Die forging allows for near-net-shape production of external parts with varying thickness, significantly reducing material waste compared to traditional machining while maintaining manufacturing feasibility through optimized forging processes
Solution Approach 2:
The invention applies preliminary action by performing die forging to create optimized blanks before final machining. The forging process pre-shapes the external parts with approximate final dimensions and thickness variations, so that subsequent machining requires minimal material removal, thereby reducing overall material loss while preparing the workpiece for precise finishing
2Volume of stationary object
If upset forging is used to produce large volume root parts, then the root can be formed, but the power of existing production means is exceeded
Solution Approach 1:
The invention segments the manufacturing process into two distinct stages: first producing optimized blanks with reduced material volume, then performing die forging to achieve the final large volume root part. This segmentation allows the use of existing press equipment by breaking down the total deformation into manageable steps, avoiding the need for excessively high power presses that would be required for single-step upset forging of large volumes
3Device complexity
If single-step die forging is used to produce primary parts, then the process is simplified, but the thickness-to-width ratio cannot be optimized for conventional machining
Solution Approach 1:
The invention uses preliminary action by implementing a multi-step die forging process where intermediate steps create optimized thickness distributions. The first forging step produces a blank with preliminary thickness optimization, and subsequent finishing steps achieve the final optimized thickness-to-width ratio required for conventional machining, demonstrating that increased process steps enable better geometric control
Solution Approach 2:
The invention applies local quality by creating different thickness regions at different stages of forging. The multi-step process allows different portions of the primary part to be forged with locally optimized thicknesses - thicker regions where material is needed and thinner regions where material should be removed - achieving non-uniform thickness distribution that optimizes the thickness-to-width ratio for subsequent conventional machining operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of large hollow blades with minimized material loss and reduced manufacturing costs, utilizing existing presses and proven machining techniques, while maintaining efficiency and effectiveness in blade production.
Implementation Method 1
die forging in multiple successive steps, using complementary dies to forge primary parts
Implementation Method 2
assembled to each other using the diffusion bonding technique
Implementation Method 3
inflation of this preform by applying gas pressure and superplastic forming of this preform
Data Source
AI summary
A method for manufacturing a hollow blade for a turbomachine is disclosed in which the blade is manufactured using a preform derived from external primary parts. A primary part including a root portion is formed by upset forging a bar in which material has been forced into a large volume area. Finish forging is done in at least two complementary stamping operations using an intermediate blank in order to limit costs and to use mechanical presses even for large and thin primary parts. Dies for forging the primary part are defined so as to double up at least the forging capacity of a press.