Finite element analysis of thermomechanical behavior and residual stresses in cold flowformed Ti6Al4V alloy

Singh, Abhishek Kumar; Narasimhan, K.; Singh, Ramesh P.

doi:10.1007/s00170-019-03609-1

Cited by 11 publications

(2 citation statements)

References 24 publications

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“…Based on the surface analysis results (Figure ), the groove structure might store the wear debris generated during the friction process, resulting in the reduction of wear debris on the surface of the grooved titanium alloy compared to the blank samples. Furthermore, the higher microhardness on the grooved surface would also reduce the shedding of debris, owing to the reduction of residual stress at the interface of the titanium alloy and Si 3 N 4 ball during the friction process. , This might lead to a decrease in deformation friction force. Additionally, after the titanium alloy was treated with laser-microgrooved texturing, the actual contact area at the friction interface became smaller than that on the Ti64 surface, and the shear strength was decreased due to the increase of microhardness.…”

Section: Discussionmentioning

confidence: 99%

Enhanced Biotribological and Anticorrosion Properties and Bioactivity of Ti6Al4V Alloys with Laser Texturing

et al. 2022

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The poor biotribological properties and bioinertness of Ti6Al4V have restricted its application in biomedical materials. In this study, microgrooves of different widths were prepared on the surface of a Ti6Al4V alloy by laser treatment. The tribological properties under dry lubrication and simulated body fluid (SBF) lubrication conditions, the electrochemical corrosion properties in SBF solution, and the bone marrow mesenchymal stem cell (BMSC) behavior on the surfaces were systematically tested. The corresponding mechanisms were discussed. The results showed that Ti6Al4V with a microgroove width of 45 μm (Ti64-45) exhibited excellent wear resistance with decreasing wear rates of 89.79 and 85.43% under dry friction and SBF lubrication compared to the Ti64 sample, which might be due to the increase of surface microhardness. Moreover, the excellent anticorrosion performance of Ti64-45 was attributed to the grain refinement on the titanium alloy surface with a lower volume fraction ratio of β phase to α phase. In addition, the microgrooves with a width of 45 μm are more conducive to BMSC proliferation and adhesion, related to promoting cell signal transduction due to cell extrusion. These studies imply that the microgroove structures are potential for application in the medical field.

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Section: Discussionmentioning

confidence: 99%

Enhanced Biotribological and Anticorrosion Properties and Bioactivity of Ti6Al4V Alloys with Laser Texturing

et al. 2022

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“…Singh A.K. et al [10] carried out a study on the staggered flow-forming using three rollers with the help of Abaqus/Explicit software. In their analysis, the rollers and mandrel were considered as rigid bodies, and an Arbitrary-Lagrangian Eulerian (ALE) meshing technique was employed to maintain mesh quality.…”

Section: Introductionmentioning

confidence: 99%

Numerical Modeling and Experimental Validation of Reverse Flow-Forming on 15CDV6 Seamless Tubes for Aerospace Application

Vikraman,

Ramesh,

Balasubramanian

2024

Preprint

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Flow-forming is an unconventional incremental forming process that involves pressing and elongating a preform kept on a rotating mandrel with the aid of rollers. A 3D thermo-mechanical model is developed to simulate the reverse flow-forming of 15CDV6 Steel. This process can produce seamless cylindrical tubes in a single step with a high strength-to-weight ratio, reducing the need for additional manufacturing processes. Flow-forming also has an inherent advantage of producing tubes with almost uniform thickness distribution. The numerical model is validated by comparing the thickness distribution of the simulated formed tubes with those obtained from the experiments. This study also investigates the effect of input variables, like, axial stagger, percentage reduction, and feed ratio, on state variables like stresses, strains, equivalent plastic strains, and the measurable output parameters. The measurable output responses, like spring-back, diametral growth, ovality, and thickness, are predicted from the numerical results. Stress and strain distribution at relevant tube regions, such as the outer circumference, inner circumference, and roller contact zone, are also investigated. In addition, a significant contribution of this work is investigation of the strain-rate history of the process, which has direct implications towards the final tube geometry and structural integrity. The results have indicated that a higher percentage reduction leads to significant plastic deformation thereby increasing spring-back and ovality. Lower feed rates are found to result in a larger area of the tube material (locally) engaging in contact with the rollers, thereby leading to a higher ovality and diametral growth. In contrast, a higher axial stagger promotes larger spacing, greater support, and a controlled deformation, resulting in lower diametral growth and spring-back. Equivalent plastic strain is a crucial numerically-measurable output for material deformation, as it indicates structural integrity and also plays a significant role in crack formation. Notably, increasing the feed ratio was found to reduce the equivalent plastic strain since the amount of local contact with the rollers is reduced. However, increasing the percentage reduction was found to increase it globally. The Taguchi method is employed to develop the design of experiments and perform optimization of the process parameters.

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A Numerical Study to Analyze the Effect of Process Parameters on Ring Rolling of Ti-6Al-4V Alloy by Response Surface Methodology

Nayak,

Singh,

Gokhale

et al. 2024

Lecture Notes in Mechanical Engineering

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Hot ring rolling is a production method to manufacture seamless rings. It is a complex incremental metal-forming process where reduction of cross-section leads to increase in diameter of the ring via circumferential extrusion. High degree of non-linearity and asymmetry is associated with the process. The process results in non-uniform distribution of temperature and plastic strain in the ring cross-section, and this in turn significantly affects the deformation behavior, microstructure, and mechanical properties. Form defect like fishtail defect is also a major concern and incurs loss in terms of labor and machining cost. In this study, rolling of Ti-6Al-4V rings is studied with the help of three-dimensional coupled thermo-mechanical finite element model established using ABAQUS/Explicit environment-based dynamic explicit code. The major parameters taken into consideration for the study are main roll speed (rpm), main roll feed (mm/s), and coefficient of friction. Each parameter was studied at two levels. Twenty simulations with different combinations of major parameters were developed via Central Composite Design (CCD). Coefficient of Variation (CoV) was used as a heterogeneity index to ascertain heterogeneity in equivalent plastic strain (PEEQ) and temperature distribution in the ring. Fishtail defect was quantified using fishtail coefficient as an index. Analysis of variance (ANOVA) was used to ascertain the impact of significant factors and interactions between different parameters affecting the ring rolling process. ANOVA technique requires unrestricted range of (−∞, ∞) for analysis. Hence, logit transformation is used to transform fishtail coefficient present in the range 0–1 to an unrestricted real number range (−∞, ∞). Main roll feed rate was found to be the most significant factor affecting CoV (PEEQ), CoV (temperature) and logit transformation of fishtail coefficient and has an inverse correlation and quadratic relationship with all the responses. Other sources of variation like main roll speed (rpm) and coefficient of friction (CoF) have minimal impact. Increase in feed rate was found to reduce CoV (PEEQ), CoV (temperature), and logit transformation of fishtail coefficient.

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Finite element analysis of thermomechanical behavior and residual stresses in cold flowformed Ti6Al4V alloy

Cited by 11 publications

References 24 publications

Enhanced Biotribological and Anticorrosion Properties and Bioactivity of Ti6Al4V Alloys with Laser Texturing

Enhanced Biotribological and Anticorrosion Properties and Bioactivity of Ti6Al4V Alloys with Laser Texturing

Numerical Modeling and Experimental Validation of Reverse Flow-Forming on 15CDV6 Seamless Tubes for Aerospace Application

A Numerical Study to Analyze the Effect of Process Parameters on Ring Rolling of Ti-6Al-4V Alloy by Response Surface Methodology

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