This thesis focuses on the forging metal forming process, and newly found techniques of geometric analysis that pertain to this operation. This project is part of an "ongoing development of a design environment that integrates models for materials and processes and allows selection and optimization of materials and manufacturing processes for components such as those used in aircraft structures and engines." The forging of axisymmetric turbine-engine disks similar to those used in aircraft engines is the focus of this project.
The objective of this project was to create low-fidelity models that deliver reasonable results in quick, cost-effective manner. Models were created using Matlab® that can greatly aid in the ability to run the simulation and optimization based design of multi-stage manufacturing processes. This project adds to the above-mentioned work, the ability to compute the minimum offset and the mutual volumetric discretization of axisymmetric disk profiles.
These programs deal with "a new process design method for controlling microstructures and mechanical properties through the optimization of preform and die shapes." The models presented here will be used to perform the "simulation of a metalforming process similar to those used for the manufacturing of turbine disks." Such a system will "allow the evaluation, with respect to quality, performance, and cost of alternate materials, processes, and process parameters for the affordable manufacturing of reliable components."