Research on shape topology preforming optimization strategy for large plate forgings
摘要
Current methods for preform shape topology optimization in large disk-like forgings often face challenges such as volume transfer mismatches and complex preform designs. This paper introduces a preform optimization strategy for large disk components, based on shape topology optimization. The proposed strategy consists of four modules: preprocessing, subunit allocation, stacking and adjustment, and automatic optimization. Additionally, the study introduces a “number of subunits-volume-number of subunits” addition/removal rule and a “column unit volume allocation strategy” to address these challenges. Large high-temperature alloy turbine disk forgings serve as the study object, with numerical simulations of the original forming process used to analyze and discuss the causes of non-uniform strain and the presence of low-strain regions. Using the proposed strategy, automated optimization was applied to the preforming of turbine disk forgings, resulting in a preform with improved volume matching and a more processable shape. The results show that applying the shape topology-based preforming design strategy reduces the strain variance in rough-machined forgings from 0.251 to 0.137, improving strain uniformity by 45% and eliminating small strain regions. The reasonableness of the preform shape and the reliability of the research method were validated through both numerical simulations and production trials.