The interest in superplasticity has increased due to the recent observations of this phenomenon in a wide range of materials, including some materials such as nanocrystalline materials 410, ceramics 411,412, metal matrix composites 4, and intermetallics 414 that are di. The claims were 1 reduced part count 2 reduced assembly time 3 weight reduction 4 monolithic parts and 5 stronger structures. The distributions of residual stress and distortion within the tool are investigated in order to evaluate the damage effects of thermomechanical loading. Finite element simulation of superplastic isothermal. In fact, flow forming can be considered to be a specialized kind of spinning process. This was intended to present the workflow in a fem simulation. Superplastic forming press fsp acb an aries alliance. Optimization of superplastic forming processes for high.
The superplastic forming technique is used to form a nearnet shape in superplastic materials, with tremendous cost savings and weight reduction potential over conventional forming processes. Typical parts produced on this type of machine are. It is now recognized as a property which can be utilized in forming processes. The stretch forming process subjects a metal blank to both plastic and elastic deformation. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming. Stretch forming process advantages and disadvantages what is stretch forming. Superplastic forming process and simulation through commercial package abaqus 6. Superplastic forming an overview sciencedirect topics. We offer complete assembly, balancing and testing services. To begin with there is the ability to form components with double curvature and smooth contours from single sheet in one operation, with exceptional dimensional accuracy and surface finish, and none of the spring back associated with cold.
Sep 18, 2017 this is the third and the final post among the series of 3 posts dedicated to superplastic forming process simulation. The practical application of technology based on superplastic forming combined with diffusion bonding spfdb to advanced aircraft engine blade manufacturing is investigated in this paper. Titanium, aluminum, and nickel based alloy parts, pylon panels, nacelle panels, firewalls, engine parts, fan and ogv. A thermomechanical stress analysis of a superplastic forming spf tool is performed by means of the finite element simulation of the whole forming process.
The principal manufacturing route used in the production of these components has been the method of superplastic forming spf. Titanium and titanium alloys superplastic forming of. It can be use for large size of it can be only used for metal sheets. This is an example of superform usas superplastic forming of aluminum, or magnesium using the cavity forming technique. Superplastic forming is a peculiarity in the mechanical behaviour of certain aluminium and titanium alloys, whereby extremely high levels of ductility can be obtained, allowing the successful forming of challenging shapes which would be otherwise impossible. Mar 25, 20 comparisonexplosive forming superplastic forming in explosive forming an in super plastic forming explosive charge is used punch or press is used to instead of a punch or press.
Superplastic forming is a process dedicated for sheet material allowing elongation of several hundred percent. Superplastic forming of advanced metallic materials 1st. The result is less waste, lower weight and manufacturing costs, high precision and lack of residual stress associated with welding which makes components ideal for aerospace, automotive and other applications. Beckwood hot forming presses offer the ultimate temperature uniformity and many efficiency features hot forming and super plastic forming on vimeo. Superplastic manufacturers, service companies and distributors are listed in this trusted and comprehensive vertical portal. Superplastic forming is a peculiarity in the mechanical behaviour of certain aluminium and titanium alloys, whereby extremely high levels of ductility can be obtained, allowing the successful forming of challenging shapes which.
Dec 31, 2017 superplastic forming spf is an industrial process used for creating precise and complex components out of certain types of materials called superplastic materials. The chinese nickelbase powder metallurgy pm superalloy fgh96, which was processed through hot isostatic pressing, is very difficult to deform. Superplastic forming is an industrial process used for creating precise and complex components out of superplastic materials. Pressurized gas typically argon on the back face of the sheet forms the material into cavity or over the surface of the tool. See how the hot forming process works from inside the press. Superplastic forming of advanced metallic materials by g.
Superplastic forming process general motors corporation. Forming times range anywhere from a few seconds to several hours, and thus cycle times are much longer than in conventional forming processes. Both metal spinning and flow forming can make workpieces from just a few inches in diameter up to several feet in diameter and lengths. Superplastic materials may be stretched in tension to elongations typically in excess of 200% and more commonly in the range of 4002000%. This program was directed at the establishment of superplastic forming of ti6al4v and ti6al2sn4zr2mo alloys as a production process. This process is usually done on a stretch press wherein the metal is gripped at the edges so that it cannot break loose. Flow forming today produces parts for the nuclear, oil and gas, chemical, and medical industries, among others. Superplastic forming acb an aries alliance company. The material is first heated up to promote superplasticity. Part of the group global strategy, aries manufacturing benefits from the same expertise chain that allowed us to stand out in the machine manufacturing field. Thermomechanical stress analysis of superplastic forming.
Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. Superplasticity the unusual ability of some metals and alloys to elongate uniformly thousands of percent at elevated temperatures, much. The comprehensive directory provides access to full contact and ability information for sourcing professionals, engineers and researchers wishing to get information on metal forming services. During spf cycles, materials such as titanium and aluminum are heated to their superplastic state. Superplastic forming, aero engine, titanium, applications, inspection.
Nov 02, 1999 the sheets were lubricated with boron nitride before superplastic forming. Recommended citation deshmukh, pushkarraj vasant, study of superplastic forming process using finite element. Superplastic forming of advanced metallic materials summarises key recent research on this important process. Fgh96 superalloy has better superplasticity in special deformation conditions and superplastic isothermal forging is the best formation method at present. Superplastic forming is a constantvolume process with a high degree of plastic deformation.
Forming studies were pursued to evaluate the process parameters of superplastic forming and to extend the process to forming aircraft structural components. The loading conditions as well the material behavior depend on the evolving grain size and grain sliding phenomenon. Superplastic forming article about superplastic forming by. Aug 22, 2012 this is an example of superform usas superplastic forming of aluminum, or magnesium using the cavity forming technique. Superplasticity is the ability of material to undergo extreme elongation allowing for deep drawn, intricate shapes. The aim is to propose the set up control of superplastic forming of aluminum alloys in an autoclave and a new strategy for rheological characterization of materials by bulge test. This way has been successfully followed in the recent past by several us car makers 1,2 and the resulting forming process has been called quick plastic forming qpf. Superplastic materials may be stretched in tension to elongations typically in excess of 200% and more commonly in. The process offers a range of important benefits, from both the design and production aspects. In the last article, i explained the 7 general steps in a fem simulation. To conduct the superplastic forming process parameter evaluation, ten specimens were machined from 0. Animation of superplastic forming process simulation of a human nose. Superplastic forming is a process by which extremely complex parts are produced from a single sheet of superplastic material.
To begin with there is the ability to form components with double curvature and smooth contours from single sheet in one operation, with exceptional dimensional accuracy and surface finish, and none of the spring back associated with cold forming techniques. Latterly, however, for titanium alloys, spf has been combined with diffusion bonding db, which, because of the compatibility of the process conditions, enables a concurrent manufacturing process spfdb to take place. Manufacturing simulation roll forming marc youtube. Finite element simulation of superplastic isothermal forging. Stretch forming is a forming process that involves metal wherein a piece of metal is stretched and bent. Superplasticity, first observed some seventy years ago, remained a scientific curiosity until about twenty years ago. Finite element simulation of superplastic isothermal forging process for nickelbase pm superalloy p.
Applications of superplastic forming and diffusion bonding to. This is the third and the final post among the series of 3 posts dedicated to superplastic forming process simulation. The sheets were lubricated with boron nitride before superplastic forming. While some similarities exist between hot forming and superplastic forming, the spf process has its own unique characteristics. May 01, 2017 ramamurthy will describe the use of systematic process improvement spi and a robustness check of a virtual stamping process.
Figure 1 shows a schematic representation of the superplastic forming process. The interface between the sensor, computer and stepper. Superplastic forming article about superplastic forming. The test results are presented graphically in figure 2. Current and likely future trends are discussed including. Aerospace complex assemblies titanium fabrications. Barnes aerospace is leading supplier for both small and large fabricated airframe and engine components for the aerospace industry. During the super plastic forming process the elevated temperature. Barnes aerospace machines complex critical components for turbine engines and is a leading supplier for highthrust, lightweight aircraft turbine engine components.
However, low production rate due to slow forming process and limited predictive capabilities due to lack of. Superform usa superplastic forming cavity forming technique. Process modeling the superplastic forming behavior of. The table here under is an indication to give you an overview of the machines we already installed.
However, low production rate due to slow forming process and limited predictive capabilities. Implicit and explicit procedures for metal forming lesson 2. The superplastic forming spf process has emerged as a reliable method of manufacturing in the aerospace industry. This technology is used for the production of complex aircraft parts. Samekto and roll 28 also found discovered certain requirements for a successful superplastic forming process. Superplastic forming spf is a wellknown and widely used sheet metal forming process especially useful for the production of very complex and light thin sheet metal components. A process for shaping superplastic materials, a unique class of crystalline materials that exhibit exceptionally high tensile ductility. Processes and equipment for superplastic forming of metals. Process potential and factors affecting formability article pdf available in mrs online proceeding library archive 601 january 2011. Superplastic forming requires material with a fine grained less than 10m, astm grain size 10 two phase structure, typically alphabeta alloys such as ti6al4v.
Firstly, similarities and differences between qpf and. Aries manufacturing is aries alliance international business brand dedicated to the production of complex parts for leading players in the aerospace industry. For the process to be successful the argon gas used must be extremely pure very low levels of oxygen and nitrogen. The superplastic behavior of a material is highly dependent on the temperature and occurs only at a narrow range of strain rates with an optimum value that is unique. Stretch forming process advantages and disadvantages. The superplastic in the name is the forming of the structure by inflation using gas. Ti 6al 4v and some stainless steels this is around 900 c 1,650 f and for aluminium alloys e. Here is the animation of the deformation history of the human nose simulation, discussed in part 2. Superplastic forming how is superplastic forming abbreviated.
The introduction of heat allows highstrength materials to be formed at significantly lower tonnages when compared to cold forming without the risk of cracking, springback, or residual stress. The grain size must be fine and usually 10 m or less, and there must be a low and. Superplastic forming 40 years and still growing springerlink. Sheet metal forming massachusetts institute of technology. Sheet metal is clamped over a male or female form tool and heated to a high enough temperature to give the material high ductility at low strain rates. Superplasticity article about superplasticity by the. Learn how new simulation software employs automatedmanual issue detection to identify local forming windows, and then proposes a combination of design variants to address these issues. The process of this invention will be illustrated with reference to figs.
1126 697 618 783 338 363 1143 522 388 37 640 517 805 443 1349 974 404 945 66 1243 760 1159 974 1269 750 1122 1357 1245 955 1263 294 1490 1423 756 246 246 822 881 381 502 876 1323 1365