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Finite element modeling and validation of springback and stress relaxation in the thermo-mechanical forming of thin Ti-6Al-4V sheets
Luleå University of Technology, Division of Mechanics of Solid Materials, Luleå, SE-971 87, Sweden; Division Materials and Production, RISE IVF AB, RISE Research Institutes of Sweden, Vällaregatan 30, Olofström, SE-293 38, Sweden.
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0002-7675-7152
Luleå University of Technology, Division of Mechanics of Solid Materials, Luleå, SE-971 87, Sweden.
2019 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015Article in journal (Refereed) Epub ahead of print
Abstract [en]

In this work, a hot forming procedure is developed using computer-aided engineering (CAE) to produce thin Ti-6Al-4V sheet components in an effective way. Traditional forming methods involve time- and cost-consuming furnace heating and subsequent hot sizing steps. A material model for finite element (FE) analyses of sheet metal forming and springback at elevated temperatures in Ti-6Al-4V is calibrated and evaluated. The anisotropic yield criterion proposed by Barlat et al. 2003 is applied, and the time- and temperature-dependent stress relaxation behavior for elastic and inelastic straining are modeled using a Zener–Wert–Avrami formulation. Thermo-mechanical uniaxial tensile tests, a biaxial test, and uniaxial stress relaxation tests are performed and used as experimental reference to identify material model parameters at temperatures up to 700 °C. The hot forming tool setup is manufactured and used to produce double-curved aero engine components at 700 °C with different cycle times for validation purposes. Correlations between the predicted and measured responses such as springback and shape deviation show promising agreement, also when the forming and subsequent holding time was as low as 150 s. The short cycle time resulted in elimination of a detectable alpha case layer. Also, the tool surface coating extends the tool life in combination with a suitable lubricant. © 2019, The Author(s).

Place, publisher, year, edition, pages
2019.
Keywords [en]
Aircraft engines; Aluminum alloys; Anisotropy; Computer aided engineering; Hot stamping; Metal forming; Sheet metal; Stress relaxation; Tensile testing; Ternary alloys; Titanium alloys; Vanadium alloys, Aero-engine components; FE analysis; Plastic anisotropy; Spring-back; Stress relaxation behavior; Temperature dependent; Ti-6 Al-4 V; Uniaxial tensile test, Finite element method
National Category
Applied Mechanics Other Materials Engineering Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:hv:diva-14478DOI: 10.1007/s00170-019-04071-9Scopus ID: 2-s2.0-85068836335OAI: oai:DiVA.org:hv-14478DiVA, id: diva2:1357064
Funder
Vinnova, 2009- 01365;2014-00919Available from: 2019-10-02 Created: 2019-10-02 Last updated: 2019-10-02

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