Investigation of Thermal-Related Effects in Hot SPIF of Ti–6Al–4V Alloy

Ortiz, Mikel; Penalva, Mariluz; Iriondo, Edurne; Lacalle, Luís Norberto López de

doi:10.1007/s40684-019-00038-z

Cited by 21 publications

(14 citation statements)

References 27 publications

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“…First, the preliminary trials have served to define the optimal working temperature (675 • C) using the current set-up. In this sense, the results have shown that, in general, within the analyzed range, a temperature increase had an overall positive effect since the positive underforming deviations that were mainly related to the springback effect decreased, in agreement with other studies [4][5][6][7]. However, this fact was not enough to obtain sufficiently accurate Ti-6Al-4V parts.…”

supporting

confidence: 87%

“…Both heating devices, one in the oven cavity and the other one around the clamping, are governed by a Programmable Logic Controller (PLC) through two pyrometers (thermocouples for the fiber blanket cover) that continuously read the sheet temperature at the center and the area close to the clamping. A backing plate below the flange zone ( Figure 3) was used to reduce the deflection observed in the area in previous experimentation [4]. The trials were performed on an in-house 5-axis gantry machine equipped with a furnace, a sheet clamping device, and a housed head that protects it against temperature increase ( Figure 2).…”

Section: Experimental Set Upmentioning

confidence: 99%

“…A set of preliminary hot SPIF trials were performed to define the optimal working temperature for the study. The geometry depicted in Figure 1 was fabricated using three different temperatures (see Table 1) within a range identified in a previous study [4]. Based also on this study's results [4], the complete forming operation was defined as a three-step operation:…”

Section: Working Variablesmentioning

confidence: 99%

“…Furthermore, excessive negative overforming deviations, mainly related to the deflection of the sheet around the perimeter area, were unavoidable despite the increasing temperature and significantly minimized percentage of deviations in the range of ±1 mm, pointing out the necessity of a specific solution for this issue. However, taking previous results [4] as a reference, this effect was considerably minimized with the presence of the backing plate, but was not sufficient to eliminate it completely.…”

mentioning

confidence: 94%

“…Sheet deflection and bending around the part perimeter, material springback after the passage of the tool, and stresses released when part unclamping or trimming affect the accuracy [3]. The use of a backing plate seems mandatory to limit deviations of the part perimeter area [4], and hot conditions can reduce the effect of springback [4][5][6][7] on parts made of Ti-6Al-4V. However, these aspects are not enough to produce accurate parts using hot SPIF and further progress is still needed in this field.…”

Section: Introductionmentioning

confidence: 99%

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Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming

Ortiz

Penalva

Iriondo

et al. 2019

Metals

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The present work focuses on the manufacturing of Ti-6Al-4V parts using hot single point incremental forming (SPIF), a non-conventional forming technology mainly oriented toward the fabrication of prototypes, spare parts, or very low volume series. In the used procedure, the entire sheet is heated and kept at uniform temperature while the tool incrementally forms the part, with the limited accuracy of the obtained parts being the major drawback of the process. Thus, this work proposes two approaches to improve the geometric accuracy of Ti-6Al-4V SPIF parts: (i) correct the tool path by applying an intelligent process model (IPM) that counteracts deviations associated with the springback, and (ii) skip overforming deviations associated with the deflection of the sheet along the perimeter of the part based on a design improvement. For this purpose, a generic asymmetric design that incorporates features of a typical aerospace Ti-6Al-4V part is used. The results point out the potential of both solutions to significantly improve the accuracy of the parts. The application of the IPM model leads to an accuracy improvement up to 49%, whereas a 25.4% improvement can be attributed to the addendum introduction. The geometric accuracy study includes the two finishing operations needed to obtain the part, namely decontamination and trimming.

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supporting

confidence: 87%

Section: Experimental Set Upmentioning

confidence: 99%

Section: Working Variablesmentioning

confidence: 99%

mentioning

confidence: 94%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming

Ortiz

Penalva

Iriondo

et al. 2019

Metals

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Single-point incremental forming of AA6061 aluminum alloy at elevated temperatures

Darzi

Mirnia

Elyasi

2021

Int J Adv Manuf Technol

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Crystal plasticity model of induction heating-assisted incremental sheet forming with recrystallisation simulation in cellular automata

Li³

et al. 2022

Int J Adv Manuf Technol

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To relate the thermomechanical behaviour and microstructural evolution of the heat-assisted incremental sheet forming (SPIF) for Ti–6Al–4 V sheet, multi-scale models based on crystal plasticity finite element model (CPFEM), representative elementary volume (RVE), and cellular automaton (CA) were established in this article. An experimental-scale CPFEM was built in advance to provide macrograin level strain, strain rate, and temperature output data, which were then used in RVE and CA as inputs to simulate the microstructural evolution throughout the SPIF process. The output results include the pole figures, dynamic recrystallisation (DRX) maps, and statistics results of the alpha (α) phase of the Ti–6Al–4 V (α-Ti) alloy from stage to stage throughout the 700 $$^\circ{\rm C}$$ ∘ C SPIF. The obtained statistics results of dislocation density, grain orientation angles, and grain size were verified with electron backscatter diffraction (EBSD). The CA analysis of the DRX progress at the upper, centre, and lower regions of the deformed workpiece has discovered that the incremental increase of the strain rate has significant effects on the dislocation density that produced a proportional relationship to the DRX percentage. The results revealed that the strain rate has strong domination in affecting the slip of grains orientation, which overcomes the effect of temperature increase in this SPIF process. Furthermore, it was found that a large amount of DRXed grains were generated at the grain boundaries, which reduced the mean grain size and increased the DRX percentage, which produced an inversely proportional relationship to the dislocation density. The thermomechanical behaviour on the SPIF workpiece was increased incrementally, which is insufficient for DRX initiation in the upper region, and the behaviour was enhanced at the centre and lower region, which can be corresponded to the microstructural evolution throughout the process.

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Investigation of Thermal-Related Effects in Hot SPIF of Ti–6Al–4V Alloy

Cited by 21 publications

References 27 publications

Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming

Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming

Single-point incremental forming of AA6061 aluminum alloy at elevated temperatures

Crystal plasticity model of induction heating-assisted incremental sheet forming with recrystallisation simulation in cellular automata

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