Superplastic Forming/Diffusion Bonding of a Titanium Alloy for the Realization of an Aircraft Structural Component in Multi-Sheets Configuration

2012 ◽  
Vol 504-506 ◽  
pp. 717-722 ◽  
Author(s):  
Luigi Carrino ◽  
Valentino Paradiso ◽  
Stefania Franchitti ◽  
Antonino Squillace ◽  
Salvatore Russo
Keyword(s):  
Diffusion Bonding ◽  
Weight Ratio ◽  
Superplastic Forming ◽  
High Strength ◽  
Production Costs ◽  
Single Shot ◽  
Forming Process ◽  
Element Analysis ◽  
Thickness Prediction ◽  
Superplastic Properties

Superplastic forming and diffusion bonding (SPF/DB) is a near-net-shape forming and joining process used with alloys having superplastic properties in order to make manufact which should have light weight and high stiffness. The aerospace is one of those sectors in which such technology is mainly used. This process allows to reduce the buy-to-fly ratio and consequently the production costs thanks to the possibility to produce complex shape components in a single shot. The material widely used for this application is the Ti-6Al-4V alloy for its high strength vs weight ratio, excellent mechanical proprieties, corrosion resistance and galvanic compatibility with carbon fiber reinforced composite materials. In this study, finite element analysis of the SPF/DB process has been carried out in order to investigate the thickness prediction, the optimization of the tooling’s geometry and the definition of the sheets initial thickness in the blow forming process of a multi-sheets configuration.

Modeling of Diffusion Bonding Time in Dissimilar Titanium Alloys: Preliminary Results

2016 ◽  
Vol 138 (12) ◽  
Author(s):  
Neha Kulkarni ◽  
M. Ramulu ◽  
Daniel G. Sanders
Keyword(s):  
Titanium Alloys ◽  
Diffusion Bonding ◽  
Weight Ratio ◽  
Superplastic Forming ◽  
High Strength ◽  
Bonding Time ◽  
Bonding Parameters ◽  
Aerospace Applications ◽  
Dissimilar Alloys ◽  
Structural Parts

Titanium alloys are excellent candidates for aerospace applications due to their high strength-to-weight ratio and corrosion resistance. In the aerospace industry, diffusion bonding (DB) combined with superplastic forming is widely adopted to produce near net shape of titanium alloy structural parts. Of all the titanium alloys, bonding parameters have been well established for producing high-quality bonds only between Ti-6Al-4V and Ti-6Al-4V. The DB of similar alloys has been modeled successfully by many researchers. However, to date the DB time has not been modeled for dissimilar alloys. In the current work, the probabilistic model developed to predict DB time in similar titanium alloys is adapted for prediction of bonding time for Ti-64SG/Ti-6Al-2Sn-4Zr-2Mo SG dissimilar titanium alloys.

Benefits of Using Diamond Dies for Cold Alternate Drawing of Magnesium Alloys

2016 ◽  
Vol 716 ◽  
pp. 13-21 ◽  
Author(s):  
Vladimir Stefanov Hristov ◽  
Kazunari Yoshida
Keyword(s):  
Magnesium Alloy ◽  
Weight Ratio ◽  
High Strength ◽  
Wire Drawing ◽  
High Ductility ◽  
Element Analysis ◽  
The Wire ◽  
Shearing Strain ◽  
Drawing Method

In recent years, due to its low density and high strength/weight ratio, magnesium alloy wires has been considered for application in many fields, such as welding, electronics, medical field (for production of stents). But for those purposes, we need to acquire wires with high strength and ductility. For that we purpose we proposed alternate drawing method, which is supposed to highly decrease the shearing strain near the surface of the wire after drawing, by changing the direction of the wire drawing with each pass and thus acquiring high ductility wires.We have done research on the cold alternate drawing of magnesium alloy wires, by conducting wire drawing of several magnesium wires and testing their strength, hardness, structure, surface and also finite element analysis, we have proven the increase of ductility at the expense of some strength.In this research we are looking to further improve the quality of the drawn wires by examining the benefits of using diamond dies over tungsten carbine dies. Using the alternate drawing method reduces the strength of the drawn wires and thus lowering their drawing limit. By using diamond dies we are aiming to decrease the drawing stress and further increase the drawing limit of the alternate drawn wires and also improve the quality of the finishing surface of the wires. With this in mind we are aiming to produce a good quality wire with low diameter, high ductility, high strength and fine wire surface.

Applying 2k Factorial Design to Study on Parameters Affecting Springback of Forming of Advanced High Strength Steel Sheets (AHSS)

2017 ◽  
Vol 872 ◽  
pp. 83-88
Author(s):  
Ramil Kesvarakul ◽  
Chamaporn Chianrabutra ◽  
Watcharapong Sirigool
Keyword(s):  
Elastic Recovery ◽  
Weight Ratio ◽  
High Strength ◽  
Die Design ◽  
Statistical Experimental Design ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Punch Radius ◽  
Springback Angle

Advanced high strength steels (AHSS) are widely used in the automotive industry due to their appropriate strength to weight ratio. This alloy has unique hardening behavior and variable unloading elastic modulus; however, the unavoidable obstacle of AHSS sheet metal forming is springback. The springback is a result of elastic recovery and residual stress. The aim of this study is to determine the proper process parameters enabling the reduction of the springback defects in AHSS forming process. This work was divided into two parts, regarding to the effects of numerical parameters and process parameter on forming AHSS. In this paper, a U-shape forming was used to examine the springback behaviors, such as springback angle, sidewall curl, and thickness, through an experiment. To achieve this purpose, 2k factorial statistical experimental design has been employed to investigate the parameters affecting the springback of forming in AHSS to find out the main effect in the springback reduction focusing on using as a guideline for die design. It showed that the blank holder force is the most influential parameter. The second is the punch radius. However, the blank holder force and punch radius is not simple to adjust in die design, the die radius becomes the important parameter to be used to reduce the springback angle.

scholarly journals Geometrical behavior of laminated graphite/epoxy composite using hypermesh

2018 ◽  
Vol 7 (2.20) ◽  
pp. 214
Author(s):  
Ch Siva RamaKrishna ◽  
KV Subba Rao ◽  
Saineelkamal Arji
Keyword(s):  
Residual Stresses ◽  
Epoxy Composite ◽  
Weight Ratio ◽  
Laminated Composite ◽  
High Strength ◽  
Element Analysis ◽  
Aspect Ratios ◽  
Military Applications ◽  
Inherent Strength

The laminated composite material is  made of ply which are specically used in automotive, aerospace and military applications due to less in weight and high strength to weight ratio. The role of structural strength is very important in composites, as the material is weak in inherent strength leads to damage of equipment made with the laminated composite. Hence, an accurate understanding of their structural geometrical behavior for residual stresses is required, such as residual stresses with different aspect ratios. In present work, various aspect ratios of laminated composite and its residual stresses are investigated using finite element analysis. The numerical results showed, on the residual stresses, that the effects the change the residual stresses due change of aspect ratio of laminated Graphite/epoxy composite. 

Determination of deformation of a highly oriented polymer under three-point bending using finite element analysis

e-Polymers ◽  
2017 ◽  
Vol 17 (1) ◽  
pp. 83-88
Author(s):  
Yi-Chang Lee ◽  
Ho Chang ◽  
Ching-Long Wei ◽  
Rahnfong Lee ◽  
Hua-Yi Hsu ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Shear Failure ◽  
Weight Ratio ◽  
High Strength ◽  
Oriented Polymer ◽  
Element Analysis ◽  
Tensile Direction ◽  
Deformation And Failure ◽  
Three Point Bending

AbstractThe molecular chains of a highly oriented polymer lie in the same direction. A highly oriented polymer is an engineering material with a high strength-to-weight ratio and favorable mechanical properties. Such an orthotropic material has biaxially arranged molecular chains that resist stress in the tensile direction, giving it a high commercial value. In this investigation, finite element analysis (FEA) was utilized to elucidate the deformation and failure of a highly oriented polymer. Based on the principles of material mechanics and using the FEA software, Abaqus, a solid model of an I-beam was constructed, and the lengths of this beam were set based on their heights. Three-point bending tests were performed to simulate the properties of the orthotropic highly oriented polymer, yielding results that reveal both tension failure and shear failure. The aspect ratio that most favored the manufacture of an I-beam from highly oriented polymers was obtained; based on this ratio, a die drawing mold can be developed in the future.

Numerical Simulation of Bulging Process of Aluminum Alloy Sheet

2013 ◽  
Vol 327 ◽  
pp. 112-116 ◽  
Author(s):  
Mao Ting Li ◽  
Yong Zhang ◽  
Chui You Kong
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Alloy Sheet ◽  
Pressure Loading ◽  
Forming Process ◽  
Element Analysis ◽  
Danger Zone ◽  
Linear Finite Element

Basing on software MSC. Marc of non-linear finite element analysis, the article has studied the material flow in the process of aluminum alloy superplastic gas bulging forming. By analyzing of the thickness distribution of the molding member it confirm the danger zone in the forming process. By analyzing of pressure loading curve influence on forming part. Because the aluminum alloy is widely used in the industrial departments, it is supposed to improve the ability of forming ability of aluminum alloy by researching the superplastic forming.

scholarly journals Finite Element Analysis of Stretch Forming of an Open Profile Made of Ultra-High Strength Martensitic MS1500 Steel

2021 ◽  
Author(s):  
Mehmet Okan Görtan ◽  
Ümit Türkmen
Keyword(s):  
Finite Element ◽  
High Strength ◽  
Roll Forming ◽  
Sheet Metals ◽  
Stretch Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Open Profile ◽  
Fe Simulations ◽  
Forming Characteristics

Stretch forming process is primarily used for generating curved structures from sheet metals such as car body panels or aircraft fuselage panels. Although there are large number of studies about stretch forming, these investigations focus mainly on flat sheet metals. However, various parts especially in the automotive industry, such as passenger car fenders are first preformed to a profile and afterwards stretch formed to generate desired final geometry. Moreover, as a consequence of weight reduction activities, these fender parts are usually made of ultra-high strength steels (UHSS) in the last two years. In the current study, stretch forming characteristics of an open profile made of martensitic UHSS (MS1500) are investigated using finite elements method (FEM). Used geometry was an asymmetrical hat profile which was preformed using roll forming prior to stretch forming. Mechanical properties of the material used is characterized using tensile test and modeled using Swift isotropic strain hardening rule. Strain and stress distribution along the bend section, geometry and springback in the final part as well as forming force have been investigated using finite element (FE) simulations. A twist has been observed in the final product along its longitudinal axis. To validate the FE results, experiments have been conducted. Twist problem is also detected in the manufactured samples. The amount of springback in produced part was similar to the experiments. It is found that FE simulations can model stretch forming process of open profiles accurately.

Testing and Modeling of Roll Levelling Process

2014 ◽  
Vol 611-612 ◽  
pp. 1753-1762 ◽  
Author(s):  
Elena Silvestre ◽  
Eneko Sáenz de Argandoña ◽  
Lander Galdos ◽  
Joseba Mendiguren
Keyword(s):  
Finite Element ◽  
High Strength Steels ◽  
Beam Theory ◽  
High Strength ◽  
Theoretical Models ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Design Engineers ◽  
Ultra High Strength Steels

Roll levelling is a forming process used to remove the residual stresses and imperfections of metal strips by means of plastic deformations. During the process the metal fibres are subjected to cyclic tension-compression deformations leading to achieve flat product. The process is especially important to avoid final geometrical errors when coils are cold formed or when thick plates are cut by laser. In the last years, and due to the appearance of high strength materials such as Ultra High Strength Steels, machine design engineers are demanding a reliable tool for the dimensioning of the levelling facilities. In response to this demand, Finite Element Analysis and Analytical methods are becoming an important technique able to lead engineers towards facilities optimization through a deeper understanding of the process. Aiming to this study two different models have been developed to analyze the roll levelling operations: an analytical model and a finite element model. The FE-analysis was done using 2D-modelling assuming plane strain conditions. Differing settings, leveller configuration and materials were investigated. The one-dimensional analytical levelling model is based on classical beam theory to calculate the induced strain distribution through the strip, and hence the evolving elastic/plastic stress distribution. Both models provide a useful guide to process-sensitivities and are able to identify causes of poor leveller performance. The theoretical models have been verified by a levelling experimental prototype with 13 rolls at laboratory.

Advanced Finite Element Analysis and Simulation in Superplastic Forming Process of Stepped Semispherical Die

2012 ◽  
Vol 12 (10) ◽  
pp. 1048-1052 ◽  
Author(s):  
P. Pradeep ◽  
S. Ayyanar ◽  
M. Balasubram ◽  
K. Ramanathan ◽  
V.S. Senthilkum
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Superplastic Forming ◽  
Forming Process ◽  
Element Analysis
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