Abstract
Isothermal local loading forming (ILLF) provides a new way to form large-scale Ti-alloy rib-web components (LTRC). However, the material undergoes complex inhomogeneous deformation in transitional region, which influences the forming quality of the component. The purpose of this paper is to improve the deformation homogeneity of the transitional region in ILLF by optimizing unequal thickness billet (UTB), which can adjust the initial volume distribution and control material flow with low cost and high efficiency. Based on the finite element (FE) simulation, the strain distribution of the transitional region in ILLF was investigated. It is found that the strain concentration at the root of formed rib in the first-loading region is more intense than that in the whole loading forming. Besides, the most strain concentration occurs at the root of partitioning rib on the side of first-loading region, which was not observed in the whole loading forming. The material transferred into the first-loading region during the second-loading step, and subsequent rib shift is the fundamental reasons for the strain concentration. The initial volume distribution of UTB has a significant effect on the strain concentration. In order to optimize the UTB, the average strain of strain concentration zone was correlated with geometric parameters of UTB by using response surface method (RSM). Based on the RSM model, the optimized UTB was achieved. The FE simulation of optimized UTB shows that the transferred material, rib shift, average strain, and maximum effective strain were all effectively decreased compared with equal thickness billet outcomes. The present RSM-based optimization method of UTB is proven to be a promising strategy to improve the deformation homogeneity of the transitional region in ILLF.
Similar content being viewed by others
References
Kleiner M, Geiger M, Klaus A (2003) Manufacturing of lightweight components by metal forming. CIRP Ann Manuf Technol 52(2):521–542
Yang H, Fan XG, Sun ZC, Guo LG, Zhan M (2011) Recent developments in plastic forming technology of titanium alloys. Sci China-Technol Sci 54(2):490–501
Gao PF, Yang H, Fan XG (2014) 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(9):1339–1347
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(21):5391–5399
Lee JJ, Jung UJ, Park GJ (2013) Shape optimization of the workpiece in the forging process using equivalent static loads. Finite Elem Anal Des 69(69):1–18
Lu B, Ou HA, Cui ZS (2011) Shape optimisation of preform design for precision close-die forging. Struct Multidisc Optim 44(6):785–796
Shao Y, Lu B, Ou H, Ren FC, Chen J (2014) Evolutionary forging preform design optimization using strain-based criterion. Int J Adv Manuf Technol 71(1):69–80
Shao Y, Lu B, Xu DK, Chen J, Ou H, Long H, Guo PY (2016) Topology-based preform design optimization for blade forging. Int J Adv Manuf Technol 86(5):1593–1650
Yang YH, Liu D, He ZY, Luo ZJ (2010) Optimization of preform shapes by RSM and FEM to improve deformation homogeneity in aerospace forgings. Chinese J Aeronaut 23(2):260–267
Gao T, Yang H, Liu Y (2008) Influence of dynamic boundary conditions on preform design for deformation uniformity in backward simulation. J Mater Process Technol 197(1):255–260
Sun ZC, Yang H, Sun NG (2009) Simulation on local loading partition during titanium bulkhead isothermal forming process. J Plasticity Eng 16(1):138–143 (in Chinese)
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
Gao PF, Li XD, Yang H, Fan XG, Lei ZN (2016) Influence of die parameters on the deformation inhomogeneity of transitional region during local loading forming of Ti-alloy rib-web component. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9443-1
Zhao XH, Zhao GQ, Wang GC, Wang TH (2002) Preform die shape design for uniformity of deformation in forging based on preform sensitivity analysis. J Mater Process Technol 128(1–3):25–32
Guan YJ, Bai X, Liu MJ, Song LB, Zhao GQ (2015) Preform design in forging process of complex parts by using quasi-equipotential field and response surface methods. Int J Adv Manuf Technol 79(1):21–29
Cai J, Li F, Liu TY (2011) A new approach of preform design based on 3D electrostatic field simulation and geometric transformation. Int J Adv Manuf Technol 56(5):579–588
Gao PF, Yang H, Fan XG, Lei PH (2015) Forming defects control in transitional region during isothermal local loading of Ti-alloy rib-web component. Int J Adv Manuf Technol 76(5):857–868
Shen CW (2007) Research on material constitution models of TA15 and TC11 titanium alloys in hot deformation process. Master thesis. Northwestern Polytechnical University, Xi’an
Zhang DW, Yang H, Li HW, Fan XG (2012) Friction factor evaluation by FEM and experiment for TA15 titanium alloy in isothermal forming process. Int J Adv Manuf Technol 60(5):527–536
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):1–12
Torabi SHR, Alibabaei S, Bonab BB, Sadeghi MH, Faraji G (2015) Design and optimization of turbine blade preform forging using RSM and NSGA II. J Intell Manuf. doi:10.1007/s10845-015-1058-0
Yang L, Wang BY, Liu G, Zhao HJ, Xiao WC (2015) Behavior and modeling of flow softening and ductile damage evolution in hot forming of TA15 alloy sheets. Mater Design 85:135–148
Wei K, Yang H, Fan XG, Gao PF (2015) Unequal thickness billet design for large-scale titanium alloy rib-web components under isothermal closed-die forging. Int J Adv Manuf Tech 81(5):729–744
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(9):2551–2562
Zhang WW, Han C, Yuan SJ (2016) Optimization of pre-form shapes by response surface methodology for hydro-forming of 780 mpa torsion beam. Int J Adv Manuf Technol 85(5):1227–1237
Guo LG, Dang L, Yang H, Zhang J, Zheng WD (2016) Identification of processing window for extrusion of large thick-walled inconel 625 alloy pipes using response surface methodology. Trans Nonferrous Met Soc China 26(7):1902–1911
Liu Y, Wang J, Wang D (2016) Numerical optimization on hot forging process of connecting rods based on RSA with experimental verification. Int J Adv Manuf Tech. doi:10.1007/s00170-016-9635-8
Zhu FY, Wang ZH, Lv M (2016) Multi-objective optimization method of precision forging process parameters to control the forming quality. Int J Adv Manuf Tech 83(9):1763–1771
Ferreira SLC, Bruns RE, Ferreira HS, Matos GD, David JM, Brandao GC, Silva EGP, Portugal LA, Reis PS, Souza AS, Santos WNL (2007) Box-Behnken design: an alternative for the optimization of analytical methods. Anal Chim Acta 597(2):179–186
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Wei, K., Fan, X., Zhan, M. et al. Improving the deformation homogeneity of the transitional region in local loading forming of Ti-alloy rib-web component by optimizing unequal-thickness billet. Int J Adv Manuf Technol 92, 4017–4029 (2017). https://doi.org/10.1007/s00170-017-0477-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0477-9