Unequal thickness billet design for large-scale titanium alloy rib-web components under isothermal closed-die forging

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• 作者：Ke Wei ; He Yang ; Xiaoguang Fan ; Pengfei Gao
• 关键词：Rib ; web component ; Unequal thickness billet ; Under ; filling defect ; Finite element simulation
• 刊名：The International Journal of Advanced Manufacturing Technology
• 出版年：2015
• 出版时间：November 2015
• 年：2015
• 卷：81
• 期：5-8
• 页码：729-744
• 全文大小：3,206 KB
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• 作者单位：Ke Wei (1)
  He Yang (1)
  Xiaoguang Fan (1)
  Pengfei Gao (1)
  
  1. State Key Laboratory of Solidification Processing, School of Materials Science and Engineering, Northwestern Polytechnical University, P.O. Box 542, Xi’an, 710072, People’s Republic China
  
• 刊物类别：Engineering
• 刊物主题：Industrial and Production Engineering
  Production and Logistics
  Mechanical Engineering
  Computer-Aided Engineering and Design
  
• 出版者：Springer London
• ISSN：1433-3015

文摘

The under-filling defect is prone to occur in the forging of large-scale titanium alloy rib-web components (LTRC). A rigorous preform design with accurate volume distribution is required for a desirable LTRC. The unequal thickness billet (UTB) design divides the preform into multiple regions of varying thickness and can not only adjust the volume distribution effectively but also control forming defects with low cost and high efficiency. The purpose of this paper is to attain LTRC without any under-filling defects using the UTB methodology. Firstly, cross sections are extracted from a desirable LTRC so as to create the initial UTB according to the calculated neutral layer of material flow between ribs. Then a finite element (FE) model is established, using the Deform-3D software for the isothermal closed-die forging to study the material flow and die cavity filling. Finally, three schemes to modify the initial UTB are proposed for those areas where there is under-filling: (I) increase the number of regions in affected areas, (II) adjust the size parameters of the regions around affected areas, and (III) increase the thickness of the regions in affected areas. In conclusion, it is found that scheme I and scheme II are based on the constancy of volume principle and can be adopted if the distribution of the ribs on those affected areas is quite simple. However, scheme I increases the complexity of the UTB, so scheme II is preferred. Alternatively, if the distribution of ribs on those regions is more complicated, scheme III can be adopted. Although the volume of the UTB is increased slightly, all ribs can be completely filled, allowing the most accurate LTRC to be produced.