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Titanium alloy is an important class of aerospace material due to its high specific strength, excellent anti-corrosion and anti-oxidation. In this paper, a three-dimensional thermo-mechanical coupled simulation was carried out to predict the formation characteristics of TC4 titanium alloy self-locking nut during the upset forging process. The stability of the upset forging was analyzed, and the influences of initial temperature and deformation velocity on the formation quality were investigated. The results show that if length-diameter ratio of the sample less than 3.27, the upset forging formation tends to be stable, and here, the length-diameter ratio of 2.89 was selected. Additionally, the forming quality of TC4 self-locking nut improves with the increase of initial temperature and decreases with the increase of the velocity of the upper die. The analysis results can provide a theoretical guidance for the upset forging formation of TC4 titanium alloy nuts.

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The reaming process of the 6061 aluminum alloy plate after cold expansion with split sleeve was simulated by finite element (FE) method based on Abaqus/CAE, the relationship between the reaming depths and the distribution of residual stress fields is obtained by analysis. The fatigue lives of the plate under different reaming depths were calculated by using the fatigue analysis software FE-SAFE, and verified by fatigue tests. The results show that reaming after expansion will increase the residual compressive stress at the hole edge on the entrance surface. In addition, the fatigue life of the specimens increases with the increase of the reaming depth, and the best fatigue gain of the specimen is obtained when the reaming depth of 0.5 mm.