Abstract
The material flow in transitional region plays an important role in the forming quality of transitional region in the isothermal local loading forming of titanium alloy large-scale rib-web component. To study the material flow in transitional region, the finite element (FE) model of transitional region was established based on DEFORM-2D software and validated by physical experiment. Then, a quick and easy method, which can measure the area of different local regions of forged part in DEFORM-2D via user subroutine, was proposed to achieve the quantitative analysis of material flow mechanism. This technique can also be used in the analysis of other forming process, such as the calculation of fill ratio in forging process. The material flow pattern of transitional region during local loading forming was analyzed step by step and compared with integral forming. The results show that the material flow of transitional region during local loading process can be divided into six stages according to the material flow pattern and load-time curve. Twice transverse material flow with opposite directions occurred in the first and second loading steps sequentially, which does not exist in the integral forming. Four characteristic values evaluating the transverse flow of material, which are associated with the formation of defects and their severities, are defined and quantitatively measured at various processing conditions. It is found that decreasing the spacer block thickness and increasing friction both can decrease the four characteristic values, thus weaken the transverse material flow, which are helpful to improve the forming quality in transitional region. However, the transverse flow of material is little affected by the loading speed.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Shen G, Furrer D (2000) Manufacturing of aerospace forgings. J Mater Process Technol 98:189–195
Zhang DW, Yang H (2013) Preform design for large-scale bulkhead of TA15 titanium alloy based on local loading features. Int J Adv Manuf Technol 67:2551–2562
Sun ZC, Yang H, Sun NG (2012) Effects of parameters on inhomogeneous deformation and damage in isothermal local loading forming of Ti-alloy component. J Mater Eng Perform 21(3):313–323
Sun ZC, Yang H (2009) Microstructure and mechanical properties of TA15 titanium alloy under multi-step local loading forming. Mater Sci Eng A 523(1–2):184–192
Fan XG, Yang H, Sun ZC, Zhang DW (2010) Effect of deformation inhomogeneity on the microstructure and mechanical properties of large-scale rib-web component of titanium alloy under local loading forming. Mater Sci Eng A 527:5391–5399
Sun ZC, Yang H (2009) Forming quality of titanium alloy large scale integral components isothermal local loading. Arab J Sci Eng 34(1C):35–45
Fan XG, Gao PF, Yang H (2011) Microstructure evolution of the transitional region in isothermal local loading of TA15 titanium alloy. Mater Sci Eng A 528(6):2694–2703
Gao PF, Yang H, Fan XG (2011) Quantitative analysis of the microstructure of transitional region under multi-heat isothermal local loading forming of TA15 titanium alloy. Mater Des 32(4):2012–2020
Zhang DW, Yang H (2013) Metal flow characteristics of local loading forming process for rib-web component with unequal-thickness billet. Int J Adv Manuf Technol 68:1949–1965
Sun Z, Yang H, Li Z (2009) H-Shaped component isothermal local loading forming of TA15 titanium alloy. Rare Metal Mater Eng 38(11):1904–1909
Sun ZC, Yang H, Sun NG (2009) Simulation on local loading partition during titanium bulkhead isothermal forming process. J Plast Eng 16(1):138–143 (in Chinese)
Zhang DW, Yang H, Sun ZC, Fan XG (2011) Deformation behavior under die partitioning boundary during titanium alloy large-scale rib-web component forming by isothermal local loading. Proceedings of the 12th World Conference on Titanium. Science Press, Beijing, p 328
Zhang DW, Yang H (2014) Distribution of metal flowing into unloaded area in the local loading process of titanium alloy rib-web component. Rare Metal Mater Eng 43(2):296–300
Zhou J, Wang F, Wang M, Xu W (2011) Study on forming defects in the rolling process of large aluminum alloy ring via adaptive controlled simulation. Int J Adv Manuf Technol 55:95–106
Saxena RK, Dixit PM (2009) Finite element simulation of earing defect in deep drawing. Int J Adv Manuf Technol 45:219–233
Wang JL, Fu MW, Ran JQ (2013) Analysis and avoidance of flow-induced defects in meso-forming process: simulation and experiment. Int J Adv Manuf Technol 68:1551–1564
Zhang DW, Yang H, Sun ZC (2010) Analysis of local loading forming for titanium-alloy T-shaped components using slab method. J Mater Process Technol 210:258–266
Zhang DW, Yang H, Sun ZC, Fan XG (2012) Deformation behavior of variable-thickness region of billet in rib-web component isothermal local loading process. Int J Adv Manuf Technol 63(1–4):1–12
Dutta A, Rao AV (1997) Simulation of isothermal forging of compressor disc by combined numerical and physical modeling techniques. J Mater Process Technol 72(3):392–395
Shen CW (2007) Research on material constitution models of TA15 and TC11 titanium alloys in hot deformation process. Master Thesis, Northwestern Polytechnical University
Tang YC, Zhou XH, Chen J (2008) Preform tool shape optimization and redesign based on neural network response surface methodology. Finite Elem Anal Des 44:462–471
Abdullah AB, Sapuan SM, Samad Z, Khaleed HMT, Aziz NA (2012) Prediction of geometric defects in the cold embossing of AA6061 aluminum alloy by finite element analysis. Sci Res Essays 7(15):1630–1638
Abdullah AB, Sapuan SM, Samad Z, Khaleed HMT, Aziz NA (2013) Numerical investigation of geometrical defect in cold forging of an AUV blade pin head. J Manuf Proc 15(1):141–150
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Gao, P., Yang, H. & Fan, X. Quantitative analysis of the material flow in transitional region during isothermal local loading forming of Ti-alloy rib-web component. Int J Adv Manuf Technol 75, 1339–1347 (2014). https://doi.org/10.1007/s00170-014-6226-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6226-4