Improving the deformation homogeneity of the transitional region in local loading forming of Ti-alloy rib-web component by optimizing unequal-thickness billet

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.