Mathematical Modeling and Finite Element Analysis of Superplastic Forming of Ti-6Al-4V Alloy in a Stepped Rectangular Die

Abstract

Superplastic forming has become a viable process in manufacturing of aircraft and automobile parts such as compressor blades, window frames and seat structures, turbine disc etc., which require relatively low tooling and assembly cost. In this paper, the attempt was made to analyze the Ti-6Al-4 V alloy sheet using a stepped rectangular die by superplastic blow forming technique. This alloy is most suitable material for producing complex shapes using superplastic forming methods. The forming characteristics of thickness distribution, bulge forming time and optimum pressure with and without die entry radius and friction coefficient in a two step rectangular die have been analyzed by the theoretical model and numerical simulation using Finite Element Method (Abaqus).