FEM Simulation On Deep Drawing Process Of Titanium Alloy TA2 Cylinder Part

Titanium alloy is widely used in aerospace industry because of its excellent properties. Titanium alloy cylinder is a universal part. But there exits lots of problems during the manufacturing. The cylinder is formed by deep drawing, a kind of panel forming technology which can get a longer cylinder. As the development of the computer hard & soft ware and the FEM (finite element method), FEM have been adopted as one of the new methods to analysis and simulate the panel forming process. FEM can forecast the forming load and the distribution of strain, stress distribution during the panel forming process. FEM also can simulate the phenomenon of wrinkle, crack and spring back. FEM can analysis the every parameter's impact to the forming process. Adopted FEM, the cost will be reduced and the engineering test cycle will be shorten. The main principle of the FEM simulation is introduced in the dissertation. The deep drawing process of the TA2 (pure titanium) cylinder is studied by FEM simulation technology in the project. A brief introduction to the project and its main results are as follows:After the thorough study of the deep drawing process of the TA2 cylinder, a practical elasto-plastic FEM model is established and the key technologic problems are dealt with reasonably. These problems include the chosen of the proper constitutive equations of the TA2, contact and the adaptive remeshing.Designed a serial of orthogonal tests about the five factors (die profile radius, gap between the punch and the die, friction between the blank and the die, punch profile radius, blank diameter) of the deep drawing process without a blank holder. Adopted the difference (At) of the maximum blank thickness subtract the minimum thickness as the index that evaluate the deep drawing process and demonstrated the rationality of this standard. The test results were analyzed by visual and variance method. Got the impact subsequence of the five factors to the process and which factor's impact is significant.The possible flaw of the mould (the disalignment of the punch & the die and non-uniform of friction between the blank and the die) are studied by FEM simulation. Got the impact regularity of the two conditions to the deep drawing process and the flaws (wrinkle and crack) of the part.Three kinds of blank shape that is circular, square, octagonal shape are formed under the same technological conditions. The processes with three kinds of blank shape were analyzed by FEM simulation. Got the impact regularity of blank shape to the deep drawing process. If blank exited flaw like small crack before forming because of manufacturing, by FEM simulation, got that the crack will be expansion during the deep drawing process. If blank exited small knob before forming because of impaction of hard body, by FEM simulation, got the impact regularity of the knob located in difference position of the blank. The regularity is to the deep drawing process.