Numerical simulation of the forging process

Titanium alloys have been used extensively in industry fields including aviation, aerospace and automobile due to their excellent comprehensive properties. Research and development of advanced plastic forming technology are of great importance to manufacturing titanium products of high performance and lightweight with low cost and short cycle. This paper analyzes the development tendencies of titanium alloy forming technology. Recent achievements in precision forming, microstructure control and multi-scale simulation of titanium alloys are reviewed. The forming techniques of large-sale integral complex components are presented.

Recent developments in plastic forming technology of titanium alloys

Different manufacturing processes can be utilized to fabricate light-weight high-strength materials for their applications in a wide spectrum of industries such as aerospace, automotive and biomedical sectors among which accumulative roll bonding (ARB) is a promising severe plastic deformation (SPD) method capable of creating ultrafine grains (UFG) in the final microstructure. The present review discusses recent advancements in the ARB process starting with the ARB basics, intricacies of the underlying mechanisms and physics, different materials, surface and rolling parameters, and finally its key effects on different properties such as strength, ductility, fatigue, toughness, superplasticity, tribology and thermal characteristics. Moreover, results of recent computational investigations have also been briefed towards the end. It is believed that ARB processing is an emerging area with tremendous opportunities in the industrial sector and ample potential in tailoring microstructures for high-performance materials.

Accumulative Roll Bonding—A Review

Some advanced plastic processing technologies and their numerical simulation

Previous sports impact reconstructions have highlighted the inadequacies in current measures to evaluate the effectiveness of personal protective equipment (PPE) and emphasised the need for improved impact surrogates that provide a more biofidelic representation of human impact response. The skin, muscle and subcutaneous adipose tissues were considered to constitute the structures primarily governing the mechanical behaviour of the human body segment. A preceding study by Payne et al. (in press) investigated the formulation and characterisation of muscle tissue simulants. The present study investigates the development of bespoke blends of additive cure polydimethysiloxane (PDMS) silicones to represent both skin and adipose tissues using the same processes previously reported. These simulants were characterised mechanically through a range of strain rates and a range of hyperelastic and viscoelastic constitutive models were evaluated to describe their behaviour. To explore the worth of the silicone simulants, finite element (FE) models were developed using anthropometric parameters representative of the human thigh segment, derived from the Visible Human Project. The multi-material silicone construction was validated experimentally and compared with both organic tissue data from literature and commonly used single material simulants: Dow Corning Silastic 3480 series silicones and ballistics gelatin when subject to a representative sports specific knee impact. Superior biofidelic performance is reported for the PDMS silicone formulations and surrogate predictions.

The evaluation of new multi-material human soft tissue simulants for sports impact surrogates

Towards a steady forming condition for radial–axial ring rolling

Dynamic explicit FE modeling of hot ring rolling process

A 3D rigid–viscoplastic FEM simulation of compressor blade isothermal forging

The influences of the material properties (hardening exponent, Young modulus and yield stress) and the forming parameters (feed amount per driving roll revolution and friction coefficient) on the T-shaped closed cold ring rolling process have been investigated through 3D-FEM. The results show that, the roll force, the roll moment and the diametrical expansion of ring lie on the hardening exponent, the roll force and the roll moment hoik, but the growth rate of ring diameter drops quickly with the increase of hardening exponent; the ring deforms more uniformly with the increase of hardening exponent, yield strength or the feed amount per driving roll revolution or with the decrease of Young's modulus; the filling capability of groove improves with the increase of yield strength but worsens with the increase of the other four variables. The achievements may serve as an important guide for selecting rolling equipment and determining the forming parameters of the process. As compared with the experimental data, the 3D-FE model of T-shaped cold ring rolling is valid, ensuring the necessary accuracy of the obtained results.

Research on the influences of material properties and forming parameters in T-shaped closed cold ring rolling process

Tube bending is a complex process with multi-factor coupling effect and multiple defects occurring. The wall thinning, as one of the important defects in tube bending, determines the bending quality. In this study, taking thin-walled 6061-T4 Al-alloy tube with Φ50.8×t0.889×R101.6mm (outer diameter D × wall thickness t × bending radius R) as the objective, the significance of processing parameters on the wall thinning degree is studied using the orthogonal test under ABAQUS/Explicit platform. The results show that: 1) the bending radius, the clearance between the tube and the pressure die, the friction between the tube and the pressure die, the clearance between the tube and the pressure die, the clearance between the tube and the mandrel and the friction between the tube and the mandrel affect the wall thinning significantly, while the coefficient of boost velocity, the number of mandrel balls, the friction between the tube and the wiper die, the mandrel extension length and the friction between the tube and the bending die have little effect on the wall thinning degree.

He Yang

Papers

Towards a steady forming condition for radial–axial ring rolling

Dynamic explicit FE modeling of hot ring rolling process

A 3D rigid–viscoplastic FEM simulation of compressor blade isothermal forging

Research on the influences of material properties and forming parameters in T-shaped closed cold ring rolling process

Significance Analysis of Processing Parameters on Wall Thinning in Tube Bending