Avoiding the folding defect and improving the die filling capability in the transitional region are desired in isothermal local loading forming of a large-scale Ti-alloy rib-web component（LTRC）. To achieve a high-pr...Avoiding the folding defect and improving the die filling capability in the transitional region are desired in isothermal local loading forming of a large-scale Ti-alloy rib-web component（LTRC）. To achieve a high-precision LTRC, the folding evolution and die filling process in the transitional region were investigated by 3 D finite element simulation and experiment using an equal-thickness billet（ETB）. It is found that the initial volume distribution in the second-loading region can greatly affect the amount of material transferred into the first-loading region during the second-loading step, and thus lead to the folding defect. Besides, an improper initial volume distribution results in non-concurrent die filling in the cavities of ribs after the second-loading step, and then causes die underfilling. To this end, an unequal-thickness billet（UTB） was employed with the initial volume distribution optimized by the response surface method（RSM）. For a certain eigenstructure, the critical value of the percentage of transferred material determined by the ETB was taken as a constraint condition for avoiding the folding defect in the UTB optimization process,and the die underfilling rate was considered as the optimization objective. Then, based on the RSM models of the percentage of transferred material and the die underfilling rate, non-folding parameter combinations and optimum die filling were achieved. Lastly, an optimized UTB was obtained and verified by the simulation and experiment.展开更多
To control the tri-modal microstructure and performance,a prediction model of tri-modal microstructure in the isothermal local loading forming of titanium alloy was developed.The staged isothermal local loading experi...To control the tri-modal microstructure and performance,a prediction model of tri-modal microstructure in the isothermal local loading forming of titanium alloy was developed.The staged isothermal local loading experiment on TA15alloy indicates that there exist four important microstructure evolution phenomena in the development of tri-modal microstructure,i.e.,the generation of lamellarα,content variation of equiaxedα,spatial orientation change of lamellarαand globularization of lamellarα.Considering the laws of these microstructure phenomena,the microstructure model was established to correlate the parameters of tri-modal microstructure and processing conditions.Then,the developed microstructure model was integrated with finite element(FE)model to predict the tri-modal microstructure in the isothermal local loading forming.Its reliability and accuracy were verified by the microstructure observation at different locations of sample.Good agreements between the predicted and experimental results suggest that the developed microstructure model and its combination with FE model are effective in the prediction of tri-modal microstructure in the isothermal local loading forming of TA15alloy.展开更多
The isothermal local loading forming technology provides a feasible way to form Ti-alloy large-scale rib-web components in aerospace and aviation fields.However,the local loading process forming limit is restricted by...The isothermal local loading forming technology provides a feasible way to form Ti-alloy large-scale rib-web components in aerospace and aviation fields.However,the local loading process forming limit is restricted by forming defects in the transitional region.In this work,the feasibility of controlling forming defects and improving the process forming limit by adjusting die parameters is explored through finite element（FE） simulation.It is found that the common cavum and folding defects in the transitional region are significantly influenced by the fillet radii of left rib and middle rib,respectively.The cavum and folding defects can be effectively controlled by increasing the fillet radii of left rib and middle rib,respectively.The process forming limits considering forming defects in the transitional region are determined by the stepwise searching method under various die parameters.Moreover,the relationship between the process forming limit and die parameters is developed through the response surface methodology（RSM）.The developed RSM models suggest that increasing the fillet radii of left and middle ribs is effective to improve the process forming limit during local loading forming of rib-web components.The results will provide technical basis for the design of die parameters and the reduction amount,which is of great importance to control forming defects and improve the process forming limit in local loading forming of Ti-alloy large-scale rib-web components.展开更多
Billet optimization can greatly improve the forming quality of the transitional region in the isothermal local loading forming （ILLF） of large-scale Ti-alloy ribweb components. However, the final quality of the tran...Billet optimization can greatly improve the forming quality of the transitional region in the isothermal local loading forming （ILLF） of large-scale Ti-alloy ribweb components. However, the final quality of the transitional region may be deteriorated by uncontrollable factors, such as the manufacturing tolerance of the preforming billet, fluctuation of the stroke length, and friction factor. Thus, a dual-response surface method （RSM）-based robust optimization of the billet was proposed to address the uncontrollable factors in transi- tional region of the ILLF. Given that the die underfilling and folding defect are two key factors that influence the forming quality of the transitional region, minimizing the mean and standard deviation of the die underfilling rate and avoiding folding defect were defined as the objective function and constraint condition in robust optimization. Then, the cross array design was constructed, a dual-RSM model was established for the mean and standard deviation of the die underfilling rate by considering the size parameters of the billet and uncontrollable factors. Subsequently, an optimum solution was derived to achieve the robust optimization of the billet. A case study on robust optimization was conducted. Good results were attained for improving the die filling and avoiding folding defect, suggesting that the robust optimization of the billet in the transitional region of the ILLF was efficient and reliable.展开更多
基金supports of the National Natural Science Foundation of China (No. 51575449)Research Fund of the State Key Laboratory of Solidification Processing (NWPU) of China (No. 104-QP2014)+1 种基金the 111 Project (No. B08040)the Fundamental Research Funds for the Central Universities (3102015AX004)
文摘Avoiding the folding defect and improving the die filling capability in the transitional region are desired in isothermal local loading forming of a large-scale Ti-alloy rib-web component（LTRC）. To achieve a high-precision LTRC, the folding evolution and die filling process in the transitional region were investigated by 3 D finite element simulation and experiment using an equal-thickness billet（ETB）. It is found that the initial volume distribution in the second-loading region can greatly affect the amount of material transferred into the first-loading region during the second-loading step, and thus lead to the folding defect. Besides, an improper initial volume distribution results in non-concurrent die filling in the cavities of ribs after the second-loading step, and then causes die underfilling. To this end, an unequal-thickness billet（UTB） was employed with the initial volume distribution optimized by the response surface method（RSM）. For a certain eigenstructure, the critical value of the percentage of transferred material determined by the ETB was taken as a constraint condition for avoiding the folding defect in the UTB optimization process,and the die underfilling rate was considered as the optimization objective. Then, based on the RSM models of the percentage of transferred material and the die underfilling rate, non-folding parameter combinations and optimum die filling were achieved. Lastly, an optimized UTB was obtained and verified by the simulation and experiment.
基金Projects(51605388,51575449)supported by the National Natural Science Foundation of ChinaProject(B08040)supported by the "111" Project,China+1 种基金Project(131-QP-2015)supported by the Research Fund of the State Key Laboratory of Solidification Processing(NWPU),ChinaProject supported by the Open Research Fund of State Key Laboratory of Materials Processing and Die&Mould Technology,Huazhong University of Science and Technology,China
文摘To control the tri-modal microstructure and performance,a prediction model of tri-modal microstructure in the isothermal local loading forming of titanium alloy was developed.The staged isothermal local loading experiment on TA15alloy indicates that there exist four important microstructure evolution phenomena in the development of tri-modal microstructure,i.e.,the generation of lamellarα,content variation of equiaxedα,spatial orientation change of lamellarαand globularization of lamellarα.Considering the laws of these microstructure phenomena,the microstructure model was established to correlate the parameters of tri-modal microstructure and processing conditions.Then,the developed microstructure model was integrated with finite element(FE)model to predict the tri-modal microstructure in the isothermal local loading forming.Its reliability and accuracy were verified by the microstructure observation at different locations of sample.Good agreements between the predicted and experimental results suggest that the developed microstructure model and its combination with FE model are effective in the prediction of tri-modal microstructure in the isothermal local loading forming of TA15alloy.
基金the support of the National Natural Science Foundation of China(Nos.51605388,51675433)111 Project(B08040)+2 种基金the Research Fund of the State Key Laboratory of Solidification Processing(NWPU)in China(Grant No.131-QP-2015)the Fundamental Research Funds for the Central Universitiesthe Open Research Fund of State Key Laboratory of Materials Processing and Die&Mold Technology at Huazhong University of Science and Technology
文摘The isothermal local loading forming technology provides a feasible way to form Ti-alloy large-scale rib-web components in aerospace and aviation fields.However,the local loading process forming limit is restricted by forming defects in the transitional region.In this work,the feasibility of controlling forming defects and improving the process forming limit by adjusting die parameters is explored through finite element（FE） simulation.It is found that the common cavum and folding defects in the transitional region are significantly influenced by the fillet radii of left rib and middle rib,respectively.The cavum and folding defects can be effectively controlled by increasing the fillet radii of left rib and middle rib,respectively.The process forming limits considering forming defects in the transitional region are determined by the stepwise searching method under various die parameters.Moreover,the relationship between the process forming limit and die parameters is developed through the response surface methodology（RSM）.The developed RSM models suggest that increasing the fillet radii of left and middle ribs is effective to improve the process forming limit during local loading forming of rib-web components.The results will provide technical basis for the design of die parameters and the reduction amount,which is of great importance to control forming defects and improve the process forming limit in local loading forming of Ti-alloy large-scale rib-web components.
基金Acknowledgements The authors would like to gratefully acknowledge the support given by the National Natural Science Foundation of China （Grant No. 51575449）, Research Fund of the State Key Laboratory of Solidification Processing （NWPU）, China （Grant No. 104-QP-2014）, 111 Project （Grant No. B08040）, and Fundamental Research Funds for the Central Universities （Grant No. 3102015AX004）.
文摘Billet optimization can greatly improve the forming quality of the transitional region in the isothermal local loading forming （ILLF） of large-scale Ti-alloy ribweb components. However, the final quality of the transitional region may be deteriorated by uncontrollable factors, such as the manufacturing tolerance of the preforming billet, fluctuation of the stroke length, and friction factor. Thus, a dual-response surface method （RSM）-based robust optimization of the billet was proposed to address the uncontrollable factors in transi- tional region of the ILLF. Given that the die underfilling and folding defect are two key factors that influence the forming quality of the transitional region, minimizing the mean and standard deviation of the die underfilling rate and avoiding folding defect were defined as the objective function and constraint condition in robust optimization. Then, the cross array design was constructed, a dual-RSM model was established for the mean and standard deviation of the die underfilling rate by considering the size parameters of the billet and uncontrollable factors. Subsequently, an optimum solution was derived to achieve the robust optimization of the billet. A case study on robust optimization was conducted. Good results were attained for improving the die filling and avoiding folding defect, suggesting that the robust optimization of the billet in the transitional region of the ILLF was efficient and reliable.
