Topology Optimization and Process Validation of a SPF/DB Cylinder Structure

CAD models were built for a three-layer SPF/DB cylinder component. FEM method was employed to simulate the SPF/DB process with different girder structure at appropriate temperature/strain rate combinations. The results show that topology parameters of the structure influence the thickness of outer sheet and surface quality. When the thickness ratio of outer sheet to inner sheet exceeded 3:1 and the angle between adjacent ribs was great than 110 degree, ribs were formed and the cylinder surface was perfect. The simulation result was verified by experiment. The experimental results showed that the optimized cylinder structure can be formed at 920°C, 1×10-4 strain rate perfectly, and the size of blank cylinder diameter can be controlled accurately by SPF/DB mold and the size deviation is less than 0.5mm.