Skip to main content
SpringerLink
Log in

Metal flow characteristics of local loading forming process for rib-web component with unequal-thickness billet

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

To explore the metal flow and filling law of large-scale rib-web component local loading forming process is important for fast design of unequal-thickness billet (UTB), parameter optimization and process control of the rib-web component local loading forming process. T-shaped component forming under UTB can reflect the forming characteristics in the large-scale rib-web component forming process. In the forming process by using UTB, the width of local loading changes dynamically, the thickness difference of billet changes notably, and the boundary conditions are very complex. By introducing new assumptions, variables and boundary conditions, a mathematical model for local loading pattern caused by UTB is established by using slab method (SM). Based on the virtualizing experimental data observed by finite element method (FEM), a predicted model for the dynamic width of local loading is established by using polynomial regression and partial least squares (PLS) regression. Comparing with FEM results indicates that the relative differences are less than about 10 % for predicted model of local loading width. Comparing with FEM and physical modeling experimental results indicates that the relative differences are less than about 15 % for SM model. The metal flow, cavity fill, and increased width of local loading under local loading condition are studied by using the mathematical models and numerical simulation, and the results indicate that: the metal flow and deformation pattern under local loading are determined by the thickness of billet and the width of local loading; the increased width of local loading is determined by initial geometric parameters, and the forming parameters such as materials (Ti-6Al-4 V and Ti-6Al-2Zr-1Mo-1 V), loading speed (0.1–1.0 mm/s), temperature (950–970 °C), etc. have little influence on it; the value of x k (position of neutral layer) under local loading pattern caused by geometric parameters of billet is less than that caused by geometric parameters of die at initial forming stage.

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

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Leyens C, Peters M (2003) Titanium and titanium alloys. Wiley-VCH, Weinheim

    Book  Google Scholar 

  2. Yang H, Fan XG, Sun ZC, Guo LG, Zhan M (2011) Recent developments in plastic forming technology of titanium alloys. Sci China Tech Sci 54:490–501

    Article  Google Scholar 

  3. Shan D, Xu W, Si C, Lu Y (2007) Research on local loading method for an aluminium-alloy hatch with cross ribs and thin webs. J Mater Process Technol 187–188:480–485

    Article  Google Scholar 

  4. Sun ZC, Yang H (2008) Mechanism of unequal deformation during large-scale complex integral component isothermal local loading forming. Steel Res Int 79(Special Edition 1):601–608

    Google Scholar 

  5. Sarkisian JM, Palitsch JR, Zecco JJ (1999) Stepped, segmented, closed-die forging, United States Patent, Patent Number: 5950481

  6. 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

    Article  Google Scholar 

  7. Altan T, et al. (1982) Modern Forging: Equipment, Materials and Process, S. Lu, translated, Defence Industrial Press, Beijing (in Chinese)

  8. Kong TF, Chan LC, Lee TC (2008) Numerical and experiment investigation perform design in non-axisymmetric warm forming. Int J Adv Manuf Technol 37:908–919

    Article  Google Scholar 

  9. Zhang DW, Yang H, Sun ZC, Fan XG (2010) A New FE Modeling Method for Isothermal Local Loading Process of Large-scale Complex Titanium Alloy Components Based on DEFORM-3D. In: Barlat F, Moon YH, Lee M-G (eds) AIP Conference Proceedings 1252. American Institute of Physics, Melville, New York, pp 439–446

    Google Scholar 

  10. Sun NG, Yang H, Sun ZC (2009) Optimization on the process of large titanium bulkhead isothermal closed-die forging. Rare Metal Mat Eng 38(7):1296–1300 (in Chinese)

    Google Scholar 

  11. 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

    Google Scholar 

  12. Park JJ, Hwang HS (2007) Preform design for precision forging of an asymmetric rib-web type component. J Mater Process Technol 187–188:595–599

    Article  Google Scholar 

  13. 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 63:1–12

    Article  Google Scholar 

  14. Altan T, Fiorentino RJ (1971) Prediction of loads and stresses in closed-die forging. J Eng Ind Trans ASME Ser B 93:477–484

    Article  Google Scholar 

  15. Chitkara NR, Aleem A (2001) Extrusion of axi-symmetric tubes from hollow and solid circular billet: a generalised slab method of analysis and some experiments. Int J Mech Sci 43:1661–1684

    Article  MATH  Google Scholar 

  16. Qwamizadeh M, Kadkhodaei M, Salimi M (2012) Asymmetrical sheet rolling analysis and evaluation of developed curvature. Int J Adv Manuf Technol 61:227–235

    Article  Google Scholar 

  17. Altan T, Oh SI, Gegel HL (1983) Metal forming: fundamentals and application. American Society for Metals, Metal Park, OH

    Google Scholar 

  18. Boër CR, Rebelo N, Rydstad H, Schröder G (1986) Process modelling of metal forming and thermomechanical treatment. Springer, Berlin

    Book  Google Scholar 

  19. O’Connell M, Painter B, Maul G, Altan T (1996) Flashless closed-die upset forging-load estimation for optimal cold header selection. J Mater Process Technol 59:81–94

    Article  Google Scholar 

  20. Wold S, Sjöström M, Eriksson L (2001) PLS-regression: a basic tool of chemometrics. Chemom Intell Lab Syst 58:109–130

    Article  Google Scholar 

  21. Wold S, Martens H, Wold H (1983) The multivariate calibration problem in chemistry solved by the PLS method. Lecture Notes in Mathematics 97:286–293

    Google Scholar 

  22. 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 60:527–536

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Northwestern Polytechnical University, 127 You Yi West Rd., P.O. Box 542, Xi’an, Shaanxi, 710072, People’s Republic of China

    Da-Wei Zhang & He Yang

  2. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, People’s Republic of China

    Da-Wei Zhang

Authors
  1. Da-Wei Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. He Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Da-Wei Zhang.

Appendix A. Abbreviations

Appendix A. Abbreviations

ETB:

Equal-Thickness Billet

FEA:

Finite Element Analysis

FEM:

Finite Element Method

GPB:

Geometric Parameters of Billet

GPD:

Geometric Parameters of Die

PLS:

Partial Least Squares

SM:

Slab Method

UTB:

Unequal-Thickness Billet

VTRB:

Variable-Thickness Region of Billet

Rights and permissions

Reprints and permissions

About this article

Cite this article

Zhang, DW., Yang, H. Metal flow characteristics of local loading forming process for rib-web component with unequal-thickness billet. Int J Adv Manuf Technol 68, 1949–1965 (2013). https://doi.org/10.1007/s00170-013-4800-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-4800-9

Keywords

Search

Navigation