Experimental and numerical investigation of the hot incremental forming of Ti-6Al-4V sheet using electrical current

Abstract

In this study, the electric hot incremental forming (EHIF) process was experimentally and numerically investigated on the Ti-6Al-4V sheet. The effect of process parameters, such as wall angle, step size, and tool diameter, was investigated on the formability, incremental forming force, and thickness distribution of samples. The results demonstrated that the incremental forming force increases with increasing the step size and decreasing the tool diameter. Also, the thickness of formed samples decreases with increasing the wall angle and decreasing the step size. In addition, the finite element modeling was used to compare the experimental and numerical results. The numerical prediction of forming force and thickness distribution was obtained and compared with experimental results and showed a good agreement.

This is a preview of subscription content, log in to check access.

References

  1. 1.

    Matsubara S (1994) Incremental backward bulge forming of a sheet metal with a hemispherical-head tool. J JSTP 35:1311–1316

    Google Scholar 

  2. 2.

    Hussain G, Gao L, Zhang ZY (2008) Formability evaluation of a pure titanium sheet in the cold incremental forming process. Int J Adv Manuf Technol 37:920–926

    Article  Google Scholar 

  3. 3.

    Aerens R, Eyckens P, Van Bael A, Duflou JR (2010) Force prediction for single point incremental forming deduced from experimental and FEM observations. Int J Adv Manuf Technol 46:969–982

    Article  Google Scholar 

  4. 4.

    Li J, Hu J, Pan J, Geng P (2012) Thickness distribution and design of a multi-stage process for sheet metal incremental forming. Int J Adv Manuf Technol 62:981–988

    Article  Google Scholar 

  5. 5.

    Mirnia MJ, Mollaei Dariani B, Vanhove H, Duflou JR (2014) Thickness improvement in single point incremental forming deduced by sequential limit analysis. Int J Adv Manuf Technol 70(9-12):2029–2041

    Article  Google Scholar 

  6. 6.

    Lee HS, Yoon JH, Park CH, Ko YG, Shin DH (2007) A study on diffusion bonding of superplastic Ti-6Al-4V ELI grade. J Mater Process Technol 187–188:526–529

    Article  Google Scholar 

  7. 7.

    Ghosh AK, Hamilton CH (1979) Mechanical behavior and hardening characteristics of a superplastic Ti-6A1-4V alloy. Metall Trans A 10A:699–706

    Article  Google Scholar 

  8. 8.

    Vanderhasten M, Rabet L, Verlinden B (2008) Ti-6Al-4V: deformation map and modelisation of tensile behaviour. Mater Des 29:1090–1098

    Article  Google Scholar 

  9. 9.

    Ambrogio G, Filice L, Manco GL (2008) Warm incremental forming of magnesium alloy AZ31. CIRP Ann Manuf Technol 57:257–260

    Article  Google Scholar 

  10. 10.

    Hussain G, Gao L, Hayat N, Dar U (2010) The formability of annealed and pre-aged AA-2024 sheets in single-point incremental forming. Int J Adv Manuf Technol 46:543–549

    Article  Google Scholar 

  11. 11.

    Lee HS, Huda Z, Iskandar Taibb N, Zahariniea T (2009) Characterization of 2024-T3: an aerospace aluminum alloy. Mater Chem Phys 113:515–517

    Article  Google Scholar 

  12. 12.

    Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2007) Laser assisted incremental forming: formability and accuracy improvement. Ann CIRP 56:273–276

    Article  Google Scholar 

  13. 13.

    Fan G, Gao L, Hussain G, Wu Z (2008) Electric hot incremental forming: a novel technique. Int J Mach Tools Manuf 48:1688–1692

    Article  Google Scholar 

  14. 14.

    Fan G, Sun F, Meng X, Gao L, Tong G (2010) Electric hot incremental forming of Ti–6Al–4V titanium sheet. Int J Adv Manuf Technol 49:941–947

    Article  Google Scholar 

  15. 15.

    Ambrogio G, Filice L, Gagliardi F (2012) Formability of lightweight alloys by Hot incremental sheet forming. Mater Des 34:501–508

    Article  Google Scholar 

  16. 16.

    Hussain G, Gao L (2007) A novel method to test the thinning limits of sheet metals in negative incremental forming. Int J Mach Tools Manuf 47:419–435

    Article  Google Scholar 

  17. 17.

    Kiranli E (2009) Determination of material constitutive equation of a biomedical grade Ti6Al4V alloy for cross-wedge rolling. A thesis submitted to the graduate school of engineering and sciences of Izmir institute of technology in partial fulfillment of the requirements for the degree of master of science in material science

  18. 18.

    Chen G, Ren C, Yang X, Jin X, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model. Int J Adv Manuf Technol 56:1027–1038

    Article  Google Scholar 

  19. 19.

    Liu R, Melkote S, Pucha R, Morehouse J, Man X, Marusich T (2013) An enhanced constitutive material model for machining of Ti–6Al–4V alloy. J Mater Process Technol 213:2238–2246

    Article  Google Scholar 

Download references

Author information

Affiliations

Authors

Corresponding author

Correspondence to M. Honarpisheh.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Honarpisheh, M., Abdolhoseini, M.J. & Amini, S. Experimental and numerical investigation of the hot incremental forming of Ti-6Al-4V sheet using electrical current. Int J Adv Manuf Technol 83, 2027–2037 (2016). https://doi.org/10.1007/s00170-015-7717-7

Download citation

Keywords

  • Hot incremental forming
  • Ti-6Al-4V
  • Forming force
  • Thickness distribution
  • FE simulation