A New FE Modeling Method for Isothermal Local Loading Process of Large-scale Complex Titanium Alloy Components Based on DEFORM-3D

Isothermal local loading process provides a new way to form large-scale complex titanium alloy components. The forming process is characterized by an extreme size (large scale in global and compared small size in regional), multi-parameter effects, and complicated loading path. To establish a reasonable finite element model is one of the key problems urgently to be solved in the research and development of isothermal local loading forming process of large-scale complex titanium alloy components. In this paper, a new finite element model of the isothermal local loading process is developed under the DEFORM-3D environment based on the solution of some key techniques. The modeling method has the following features: (1) different meshing techniques are used in different loading areas and the number of meshed elements is determined according to the deformation characteristic in different local loading steps in order to improve computational efficiency; (2) the accurate magnitude of the friction factor under titanium alloy hot forming (isothermal forming) condition is adopted instead of the typical value for lubricated hot forming processes; (3) different FEM solvers are chosen at different stages according to the loading characteristic and the contact state; (4) in contrast to the local component model, a full 3D component is modeled to simulate the process. The 3D-FE model is validated by experimental data of a large-scale bulkhead forming under isothermal local loading. The model can describe the quantitative relationships between the forming conditions and the forming results. The results of the present study may provide a basis for studying the local deformation mechanism, selecting the reasonable parameters, optimizing the die design and the process control in isothermal local loading process of large-scale complex titanium alloy components.