EPSRC logo

Details of Grant 

EPSRC Reference: EP/C004140/1
Title: 3D Die Shape Optimisation for Net-Shape Forging of Aeroengine Compressor Blades
Principal Investigator: Ou, Dr H
Other Investigators:
Armstrong, Professor CG
Researcher Co-Investigators:
Project Partners:
Rolls-Royce Plc (UK)
Department: Sch Mechanical and Aerospace Engineering
Organisation: Queen's University of Belfast
Scheme: Standard Research (Pre-FEC)
Starts: 01 August 2005 Ends: 31 July 2008 Value (£): 238,917
EPSRC Research Topic Classifications:
Manufacturing Machine & Plant
EPSRC Industrial Sector Classifications:
Aerospace, Defence and Marine
Related Grants:
Panel History:  
Summary on Grant Application Form
Forging aeroengine components is challenging due to the stringent process cost and quality requirements and especially the dimensional and shape specifications. Current forging design is very much dependent upon the designer's knowledge and iterative forging trials. Even in routine production, considerable post-forging corrections are often required, which causes increased production time and possible scrap. The aim of the project is to develop a novel 3D die shape optimisation system for net-shape forging of aeroengine blade components. The unique features of this system are a novel computational formulation to quickly quantify dimensional and shape errors of forged blades, a robust optimisation method to efficiently derive optimised die shapes for forging design utilising generic process simulation and optimisation techniques, and a framework of numerical simulation and robust design functionalities to fully integrate forging design and manufacturing. The work will be validated by forging trials and inspections conducted in collaboration with the industrial partner, Rolls-Royce plc. Such a forging optimisation system will enable the industrial partner to improve forging design and production efficiency. It would enhance the competitive position of the UK aeroengine industry and have immediate impact in other sectors such as automotive industry. The use of process simulation to conduct numerically the experiments required for process optimisation and 6-sigma quality enhancement would have very wide applicability.
Key Findings
This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
Potential use in non-academic contexts
This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
Impacts
Description This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
Summary
Date Materialised
Sectors submitted by the Researcher
This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
Project URL:  
Further Information:  
Organisation Website: http://www.qub.ac.uk