Advertisement

Experimental analysis of electro-assisted warm spin forming of commercial pure titanium components

  • Kai Jin
  • Jianhua Wang
  • Xunzhong Guo
  • Joseph Domblesky
  • Hui Wang
  • Xia JinEmail author
  • Runze Ding
ORIGINAL ARTICLE

Abstract

Aircraft manufacturers continue to use larger quantities of titanium components to increase strength and reduce weight. While various forming processes can be used, spin forming is particularly well suited for economically producing small and large quantities of axisymmetric parts. However, due to its limited formability at room temperature, titanium is typically warm formed. In the study, a new type of electro-assisted warm spin forming method based on the electroplasticity effect is presented. Experimental results show that electro-assisted forming technology can significantly improve forming quality of titanium parts. Advantages of the method include short forming times, uniform temperature distribution, simple operation, and convenient control. The influence of process parameters, including current intensity, feed rate, spindle speed, and lubrication, on the formability of commercial pure titanium sheets was systematically analyzed using an industrial spinning machine. It was found that deformation is mainly concentrated in the arc phase of the curved generatrix. Finally, components were subjected to uniaxial tensile stress and biaxial compressive stress based on previously defined forming limit curves. The technology is feasible and easy to control and has the potential for application to other rotary sheet forming technologies.

Keywords

Electro-assisted spin forming Joule heating Strain analysis Electroplasticity effect Formability Warm forming 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This work was supported by the National Natural Science Foundation of Jiangsu Province (No. BK20170788), Postgraduate Research & Practice Innovation Program of Jiangsu Province (No. SJCX18_0106), and the National Key Research and Development Program of China (No. 2017YFB0703301).

References

  1. 1.
    Wang YH, Xia QX, Yang MH, Cheng XQ (2005) Development course and the present research of the CNC spinning machine [J]. Forging & Stamping. Technology:1547–1552Google Scholar
  2. 2.
    Jahedi M, Zahiri S, Gulizia S, Tiganis B, Tang C, Fraser D (2009) Direct manufacturing of titanium parts by cold spray. Mater Sci Forum 618–619:505–508CrossRefGoogle Scholar
  3. 3.
    Imam MA, Froes FH, Housley KL (2010) Titanium and titanium alloys [M]. Kirk-Othmer encyclopedia of chemical technology. John Wiley & Sons, Inc 24–29Google Scholar
  4. 4.
    Guan L, Tang GY, Chu PK (2010) Recent advances and challenges in electroplastic manufacturing processing of metals [J]. J Mater Res 25(7):1215–1224CrossRefGoogle Scholar
  5. 5.
    Han D, Chen H (1999) Effect of temperature gradient on quality of TAl spinning cylinders [J]. Solid Rocket Technol 1:72–74Google Scholar
  6. 6.
    Wang CH, Liu KH, Zhou L (2017) Spinning technology [M]. Fujian Sci Technol Press 2(4):145–147Google Scholar
  7. 7.
    Okazaki K, Kagawa M, Conrad H (1980) An evaluation of the contributions of skin, pinch and heating effects to the electroplastic effect in titatnium [J]. Mater Sci Eng 45(2):109–116CrossRefGoogle Scholar
  8. 8.
    Sprecher AF, Mannan SL, Conrad H (1983) On the temperature rise associated with the electroplastic effect in titanium [J]. Scr Metall 17(6):769–772CrossRefGoogle Scholar
  9. 9.
    Roschupkin AM, Bataronov IL (1996) Physical basis of the electroplastic deformation of metals [J]. Russ Phys J 39(3):230–236CrossRefGoogle Scholar
  10. 10.
    Salandro WA, Bunget C, Mears L (2011) Thermo-mechanical investigations of the Electroplastic effect [C]. ASME 2011 Int Manuf Sci Eng Conf:573–582Google Scholar
  11. 11.
    Salandro WA, Bunget CJ, Mears L (2011) Several factors affecting the Electroplastic effect during an electrically-assisted forming process [J]. J Manuf Sci Eng 133(6):204–212CrossRefGoogle Scholar
  12. 12.
    Xie HY, Dong XH, Liu K, Ai ZQ, Peng F, Wang Q, Chen F, Wang JF (2015) Experimental investigation on electroplastic effect of DP980 advanced high strength steel. Mater Sci Eng A 637:23–28CrossRefGoogle Scholar
  13. 13.
    Conrad H (2000) Electroplasticity in metals and ceramics [J]. Mater Sci Eng A 287(2):276–287CrossRefGoogle Scholar
  14. 14.
    Nguyen-Tran HD, Oh HS, Hong ST, Han HN, Cao J, Ahn SH, Chun DM (2015) A review of electrically-assisted manufacturing [J]. Int J Precision Eng Manuf-Green Technol 2(4):365–376CrossRefGoogle Scholar
  15. 15.
    Zhu Z, Dhokia VG, Nasshi A, Newman ST (2013) A review of hybrid manufacturing processes-state of the art and future perspectives [J]. Int J Comput Integr Manuf 26(7):596–615CrossRefGoogle Scholar
  16. 16.
    Chu WS, Kim CS, Lee HT, Choi JO, Park JI, Song JH, Jang KH, Ahn SH (2014) Hybrid manufacturing in micro/nano scale: a review [J]. Int J Precis Eng Manuf-Green Technol 1(1):75–92CrossRefGoogle Scholar
  17. 17.
    Sim MS, Lee CM (2014) A study on the laser preheating effect of Inconel 718 specimen with rotated angle with respect to 2-axis [J]. Int J Precis Eng Manuf 15(1):189–192CrossRefGoogle Scholar
  18. 18.
    Lin YC, Chuang FP, Wang AC, Chow HM (2014) Machining characteristics of hybrid EDM with ultrasonic vibration and assisted magnetic force [J]. Int J Precis Eng Manuf 15(6):1143–1149CrossRefGoogle Scholar
  19. 19.
    Park C, Shin BS, Kang MS, Ma YW, Oh JY, Hong SM (2015) Experimental study on micro-porous patterning using UV pulse laser hybrid process with chemical foaming agent [J]. Int J Precis Eng Manuf 16(7):1385–1390CrossRefGoogle Scholar
  20. 20.
    Lee SJ, Kim JD, Suh J (2014) Microstructural variations and machining characteristics of silicon nitride ceramics from increasing the temperature in laser assisted machining [J]. Int J Precis Eng Manuf 15(7):1269–1274CrossRefGoogle Scholar
  21. 21.
    Cho YT, Na SJ (2015) Numerical analysis of plasma in CO2 laser and arc hybrid welding [J]. Int J Precis Eng Manuf 16(4):787–795CrossRefGoogle Scholar
  22. 22.
    Fan GQ, Gao L, Hussain G, Wu ZL (2008) Electric hot incremental forming: a novel technique [J]. Int J Mach Tool Manu 48(15):1688–1692CrossRefGoogle Scholar
  23. 23.
    Fan GQ, Gao L (2014) Mechanical property of Ti-6Al-4V sheet in one-sided electric hot incremental forming [J]. Int J Adv Manuf Technol 72(5–8):989–994CrossRefGoogle Scholar
  24. 24.
    Fan GQ, Sun FT, Meng XG, Gao L, Tong GQ (2010) Electric hot incremental forming of Ti-6Al-4V titanium sheet [J]. Int J Adv Manuf Technol 49(9–12):941–947CrossRefGoogle Scholar
  25. 25.
    Honarpisheh M, Abdolhoseini MJ, Amini S (2016) Experimental and numerical investigation of the hot incremental forming of Ti-6Al-4V sheet using electrical current [J]. Int J Adv Manuf Technol 83(9–12):2027–2037CrossRefGoogle Scholar
  26. 26.
    Ross CD, Kronenberger TJ, Roth JT (2009) Effect of DC on the Formability of Ti-6Al-4V[J]. J. Eng. Mater. Technol 131(1):031004Google Scholar
  27. 27.
    Perkins TA, Kronenberger TJ, Roth JT (2007) Metallic forging using electrical flow as an alternative to warm/hot working [J]. J Manuf Sci Eng 129(1):84–94CrossRefGoogle Scholar
  28. 28.
    Magargee J, Morestin F, Cao J (2013) Characterization of flow stress for commercially pure titanium subjected to electrically assisted deformation [J]. J Eng Mater Technol 135(4):041003CrossRefGoogle Scholar
  29. 29.
    Jiang SS, Tang ZJ, Du H, Chen J, Zhang JT (2017) Research progress of current assisted forming process for titanium alloys [J]. Precis Form Eng 9(2):7–13Google Scholar
  30. 30.
    Zhang T (2009) Spin forming process [M]. Chem Ind Press 3(4):45Google Scholar
  31. 31.
    Prakash R, Singhal RP (1995) Shear spinning technology for manufacture of long thin wall tubes of small bore [J]. J Mater Process Technol 54(1–4):186–192CrossRefGoogle Scholar
  32. 32.
    Pham QT, Kim YS (2016) Evaluation of press formability of pure titanium sheets [J]. Key Eng Mater 716(3):87–98CrossRefGoogle Scholar
  33. 33.
    Gao RY (1982) Hot spinning process of TA2 titanium plate [J]. Aeronaut Manuf Technol 7:10–13Google Scholar
  34. 34.
    Xu SH, Wang XQ (2000) Progress in the determination of friction coefficient in sheet forming [J]. J Plast Eng 7(2):40–43Google Scholar
  35. 35.
    Okazaki K, Kagawa M, Conrad H (1978) A study of the electroplastic effect in metals [J]. Scr Metall 12(11):1063–1068CrossRefGoogle Scholar
  36. 36.
    Zhan M, Yang H, Zhang JH, Xu YL, Ma F (2007) 3D FEM analysis of influence of roller feed rate on forming force and quality of cone spinning [J]. J Mater Proc Technol 187–188(12):486–491CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Kai Jin
    • 1
  • Jianhua Wang
    • 1
  • Xunzhong Guo
    • 2
  • Joseph Domblesky
    • 3
  • Hui Wang
    • 1
  • Xia Jin
    • 1
    Email author
  • Runze Ding
    • 1
  1. 1.College of Mechanical and Electrical EngineeringNanjing University of Aeronautics and AstronauticsNanjingPeople’s Republic of China
  2. 2.College of Material Science and TechnologyNanjing University of Aeronautics and AstronauticsNanjingPeople’s Republic of China
  3. 3.Department of Mechanical EngineeringMarquette UniversityMilwaukeeUSA

Personalised recommendations