Abstract
To investigate and verify the degree to which the forming properties of low plasticity materials are improved at room temperature using the granular medium forming (GMF) process at 500 °C, a coupled Eulerian–Lagrangian unit calculation model was established and a special mold was designed to conduct a GMF experiment for titanium alloy sheets under different-shaped pressing blocks. Then, using a three-coordinate measuring machine, the sizes of the outer contours of the parts formed at room temperature were measured, and the results showed that the bottom of the parts maintained a smooth surface during the drawing process. As the drawing height increased, the radius of curvature of the cambered surface gradually decreased. By measuring the wall thickness of the parts at different positions from the central axis using a caliper, the wall thickness distribution curves of these parts were obtained, which showed that the deformations of the bottom of the formed parts were uniform and the uniformity of the wall thickness distribution was good. By comparing the GMF experimental data at 500 °C with traditional deep drawing experimental data, it was found that the GMF technology could improve the forming properties of low plastic materials such as titanium alloys.
Highlights
The granular medium forming (GMF) process, which uses solid granules as a pressuretransfer medium in order to form a workpiece, is a newly proposed flexible die-forming technique [1,2,3,4]
Because the application of this process can fully exploit recent advances in the formability of lightweight materials at elevated temperatures, as well as overcome the limitations that the heat-resistant oil used in warm hydroforming operations can withstand temperatures of no more than 350 ◦ C [5,6,7] and that the inert gas used at higher temperatures in hot pneumatic bulging processes usually causes leakage problems [8,9], the GMF process has recently attracted considerable attention by several researchers [10,11,12]
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Summary
The granular medium forming (GMF) process, which uses solid granules as a pressuretransfer medium in order to form a workpiece, is a newly proposed flexible die-forming technique [1,2,3,4]. GMF is applied mainly in the fabrication of thin-walled lightweight components such as titanium alloys and high-strength steel parts at relatively high temperatures The finite element analysis (FEA) method was used to simulate the GMF process of a titanium alloy sheet [4]. To evaluate the accuracy of the model and verify the forming properties of low plastic materials at room temperature (RT), an experimental investigation of the GMF process on a titanium alloy sheet at 500 ◦ C was carried out. A free deep drawing experiment on titanium alloy sheets under different conditions was conducted using a self-designed mold, and the feasibility of using GMF at elevated temperatures to fabricate complex thin-walled parts was initially shown to be viable. As this study presents a new and precise forming manufacturing approach, it is important to carry out further studies of the forming method for complex thin-walled parts at elevated temperatures [20,21,22]
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