Abstract
In order to integrally manufacture the large TC4 titanium alloy part, an electrically-assisted incremental forming process is cleverly proposed to solve the traditional hot forming disadvantages of expensive heating furnaces and long cycle period. The two-step simulation method including thermal-electricity coupling simulation and thermo-mechanical coupling simulation was selected to predict the temperature variations and the sheet deformation behaviors. The electrically-assisted incremental forming experiment of thin TC4 titanium alloy sheet was performed. The highest prediction error is 6% for springback angles. The thrice forming at 10.9 A/mm2 satisfies the precision requirement of the designed part. Therefore, the two-step simulation method can effectively calculate the electrically-assisted incremental process. The electrically-assisted incremental forming technique is very promising for the integral producing large titanium alloy part.
Highlights
Titanium alloys are used in a wide range of industries, including aerospace, surgical implants, and fuel cells owing to their excellent properties such as moderately high specific strength, good toughness, and excellent corrosion resistance [1,2,3]
The development of advanced electrically-assisted forming (EAF) technology has been a promising method of solving the bad plasticity of titanium alloys at room temperature
Utilizing electric current in the forming process causes a primary benefit of rapid heating to a desired temperature for either warm or hot forming process, while averting the demand for expensive heating furnaces and long heating/cycle period [4]
Summary
Titanium alloys are used in a wide range of industries, including aerospace, surgical implants, and fuel cells owing to their excellent properties such as moderately high specific strength, good toughness, and excellent corrosion resistance [1,2,3]. The development of advanced electrically-assisted forming (EAF) technology has been a promising method of solving the bad plasticity of titanium alloys at room temperature. It utilizes the electroplastic effects brought by the electric current flowing through metals to assist the deformation of low plasticity materials. Jiang et al [6] conducted both electrically assisted tension and pre-treatment tension to compare different effects on deformation resistance reduction and ductility improvement of TC4 titanium alloy. Conducted uniaxial tension tests on thin commercially pure titanium sheets subjected to electrically assisted deformation using a new experimental setup to decouple thermal-mechanical and possible electroplastic behavior. Subsequent electrically-assisted incremental forming tests were conducted to reveal the relation between process parameters and forming quality
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