An Investigation of the Effective Factors in the Shape Rolling Process of a Compressor Blade

Document Type : Research Paper

Authors

1 Department of Mechanical Engineering, Faculty of Engineering, Urmia University, Urmia, Iran

2 Department of Industrial Engineering, Faculty of Engineering, Urmia University, Urmia, Iran

3 Faculty of Mechanical Engineering, Urmia University of Technology, Urmia, Iran

10.22099/ijmf.2020.37104.1156

Abstract

One of the most popular forming processes is the shape rolling process in which the desired shape change is achieved by pressing two rollers with a special shape in the opposite rotational direction. In order to improve the product’s quality and reduce production costs, accurate analysis of the shape rolling process of the compressor blades as well as the investigation of the effective parameters have been done. First, the shape rolling process of a typical compressor blade was simulated based on the experimental data using the finite element method and Design of Experiment (DOE). Then, the effect of various process parameters, including the thickness and width of the preform, the roller diameter, the thickness and width of the flash channel, and the number of the rolling steps on two objectives, namely the rolling force and the amount of the flash were investigated. The obtained data were analyzed by Analysis of Variance (ANOVA), and the contributory factors of the shape rolling process were identified. The results revealed that all of the considered factors affected the rolling load, but only the initial sheet's width and thickness were the factors with impact on the volume of the flash as the second objective. The required process load decreased by increasing the number of the rolling steps, but the rolling load increased by increasing other factors. Furthermore, increasing the thickness and width of the initial sheet increased the flash volume.

Keywords


[1] S. R. Motallebi, Investigation of influence parameters on the hot rolling process using finite element method, in Proceeding of 2nd International Conference on Engineering Optimization  (2010) 332-338.
[2] A. Handbook, Forming and Forging, The Material Information Society 14 (1988).
[3] J. B. Griffith, H. C. Sanborn, Method for the manufacture of metal vanes for turbomachinery, Google Patents, (1985).
[4] V. Medvedev, I. Mogilevskii, V. Eremeev, Rolling blanks for turbine stator blades, Metallurgist 15(10) (1971) 679-681.
[5] D. Lambert, P.R. Jepson, J. Yang, Process simulation for industrial rolling applications, In MS&T Conference Proceedings, Columbus, OH,ASM International (2004).
[6] R. Grishman, B. Sundheim, Message understanding conference-6: A brief history, in Proceeding of the conference distributed by Morgan Kaufmann Publishers, (1996).
[7] F. Bacchus, AIPS 2000 planning competition: The fifth international conference on artificial intelligence planning and scheduling systems, Ai magazine 22(3) (2001) 47-47.
[8] Q. Jin, Geometric accuracy design method of roller cavity surfaces for net-shape rolling compressor blades, Open Access Library Journal 6(3) (2019) 1.
[9] Q. Jin, W. Wang, W. Yan, R. Jiang, Springback and forward slip compensation in designing roller cavity surfaces for net-shape rolling compressor blades, Materials and Manufacturing Processes 32(12) (2017) 1442-1449.
[10] V. N. Potluri, Master of Science Degree in Mechanical Engineering, Department of Mechanical Engineering Howard R. Hughes College of Engineering, Thesis, University of Nevada, Las Vegas (2004).
[11] T. Altan, G. Ngaile, G. Shen, Cold and hot forging: fundamentals and applications, ASM international (2004).
[12] D. C. Montgomery, Design and analysis of experiments, John wiley & sons (2017).