Virtual titanium fabrication - mechanical cutting and forming including demonstrator

Purpose and goal

In this project mechanical cutting and hot forming in titanium were studied. In the project, a method for particle FEM analyses of 2D problems such as turning was developed and calibration of a physically based material model was performed. Also, a hot forming process for titanium geometries of commercial interest to GKN were further developed. The project contribute to the possibility of using FEA in the design of fabricated engine structures and that SME can further develop necessary skills in order to produce desired titanium parts of interest to the Aerospace industry.

Expected results and effects

A PFEM-method for analyses of mechanical cutting was developed. In combination with a physically based material model for titanium, promising agreement with experimental results such as tool forces, chip formation and residual stresses was shown. A method for thermo-mechanical biaxial testing of anisotropic materials has been developed. Also, a hot forming procedure for a titanium part of interest to GKN has been further developed by FE-analyses. The project strongly contributes to the possibility of commercialization of hot forming in which Swedish companies can participate.

Planned approach and implementation

The Project combine theoretical research activities with experimental studies and validation testing of hot forming and turning in Ti-6Al-4V. Advanced thermo-mechanical FE-analyses has together with competence and equipment at SMF created the possibilities necessary to fulfill the project activities; development of FE-methods, perform advanced experiments, produce parts within tolerances for production, identify new research challenges and initiate international research collaboration with potential to perform excellent and leading research within the area.