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Details of Grant 

EPSRC Reference: GR/R19861/01
Title: Die Shape Optimisation and Sensitivity Analysis In Forging Gas Turbine Compressor Blades
Principal Investigator: Ou, Dr H
Other Investigators:
Armstrong, Professor CG Price, Professor M
Researcher Co-Investigators:
Project Partners:
Rolls-Royce Plc (UK)
Department: Mechanical & Manufacturing Engineering
Organisation: Queen's University of Belfast
Scheme: Fast Stream
Starts: 01 December 2001 Ends: 30 September 2003 Value (£): 61,742
EPSRC Research Topic Classifications:
Materials testing & eng.
EPSRC Industrial Sector Classifications:
Aerospace, Defence and Marine
Related Grants:
Panel History:  
Summary on Grant Application Form
Net-shape forging of high temperature alloys into compressor blades is difficult to achieve due to the fact that many factors such as preform shape, material flow-stress, die-elasticity, interfacial properties and temperature conditions influence the forging process and final accuracy. In order to achieve net-shape forging of compressor blades for aerospace application, process simulation and design of forging die/tool set-up are commonly used in the process/tool design activities, but both of which require trial and error, which is very time consuming.This project is intended to develop a die shape optimisation and sensitivity analysis system for forging of compressor blades by integrating existing geometric modelling, FE simulation packages and optimisation algorithms. The objective is to derive the optimal forging die shape which aims at eliminating the form errors of forged blades due to die-elasticity, variation of forging temperature and process conditions. Using the results from the developed sensitivity analysis models of forging accuracy, material flow-stress and temperature, most influencing factors can be identified and further evaluated which enable in depth knowledge of the forging process and ultimately lead to optimal process design in terms of forging quality and accuracy. The developed process optimisation system will not only be sufficiently flexible to accommodate a variety of blade dimensions, material properties and process conditions but also be transferable to other precision forging processes with wider application.
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Organisation Website: http://www.qub.ac.uk