Optimising pressure profiles in superplastic forming

Abstract

Some metals, such as Ti-6Al-4V, have a high elongation to failure when strained at certain rates and temperatures. Superplastic forming is the utilisation of this property, and it can be used to form thin, geometrically complex components. Superplastic forming is a slow process, and this is one of the reasons why it is an expensive manufacturing process. Localised thinning occurs if the specimen is strained too quickly, and components with locally thin wall thickness fail prematurely. The goal of this study is to find a technique that can be used to minimise the forming time while limiting the minimum final thickness. The superplastic forming process is investigated with the finite element method. The finite element method requires a material model which describes the superplastic behaviour of the metal. Several material models are investigated in order to select a material model that can show localised thinning at higher strain rates. The material models are calibrated with stress-strain data, grain size-time data and strain rate sensitivity-strain data. The digitised data from literature is for Ti-6Al-4V with three different initial grain sizes strained at different strain rates at 927 C. The optimisation of the forming time is done with an approximate optimisation algorithm. This algorithm involves fitting a metamodel to simulated data, and using the metamodels to find the optimum instead of using the finite element model directly. One metamodel is fitted to the final forming time results, and another metamodel is fitted to the final minimum thickness results. A regressive radial basis function method is used to construct the metamodels. The interpolating radial basis function method proved to be unreliable at the design space boundaries due to non-smooth finite element results. The non-smooth results are due to the problem being path dependent. The final forming time of the superplastic forming of a rectangular box was successfully minimised while limiting the final minimum thickness. The metamodels predicted that allowing a 4% decrease in the minimum allowable thickness (1.0 mm to 0.96 mm) and a 1 mm gap between the sheet and the die corner the forming time is decreased by 28.84%. The finite element verification indicates that the final minimum thickness reduced by 3.8% and that the gap between the sheet and the die corner is less than 1 mm, resulting in the forming time being reduced by 28.81%.