Three-dimensional finite element modelling of a titanium aluminide aerofoil forging

Aerofoils represent one of the more difficult problems for forging modelling using the finite element technique due to the complex geometries involved combined with the non-linear nature of the plasticity encountered in real materials. The work described in this paper covers the incorporation of a material flow stress model into two finite element (FE) codes (ABAQUS and FORGE-3) which were then used to simulate the forging of a gas turbine blade. The results obtained have been compared with real data from actual forged components. The material model developed describes not only the flow softening behaviour of titanium aluminide during hot deformation but also allows the microstructural evolution to be determined. The results obtained from both FE models gave reasonable predictions of the actual press loads and the component shape while the microstructural observations were in good agreement with the modelling. (C) 1998 Elsevier Science S.A. All rights reserved.