Springback prediction and validation in hot forming of a double-curved component in alloy 718

• The demands associated with the production of advanced parts made of nickel-base superalloys are continuously increasing to meet the requirements of current environmental laws. The use of lightweight components in load-carrying aero-engine structures has the potential to significantly reduce fuel consumption and greenhouse gas emissions. Furthermore, the competitiveness of the aero-engine industry can benefit from reduced production costs and shorter development times while minimizing costly try-outs and increasing the efficiency of engines. The manufacturing process of aero-engine parts in superalloys at temperatures close to 950 °C produces reduced stamping force, residual stresses, and springback compared to traditional forming procedures occurring at room temperature. In this work, a hot forming procedure of a double-curved component in alloy 718 is studied. The mechanical properties of the material are determined between 20 and 1000 °C. The presence and nature of serrations in the stress–strain curves are assessed. The novel version of the anisotropic Barlat Yld2000-2D material model, which allows the input of thermo-mechanical data, is used in LS-DYNA to model the behaviour of the material at high temperatures. The effect of considering the stress-relaxation data on the predicted shape distortions is evaluated. The results show the importance of considering the thermo-mechanical anisotropic properties and stress-relaxation behaviour of the material to predict the final geometry of the component with high accuracy. The implementation of advanced material models in the finite element (FE) analyses, along with precise process conditions, is vital to produce lightweight components in advanced materials of interest to the aerospace industry.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Bearbetnings-, yt- och fogningsteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Manufacturing, Surface and Joining Technology (hsv//eng)

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Metallurgi och metalliska material (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Metallurgy and Metallic Materials (hsv//eng)

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik -- Teknisk mekanik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering -- Applied Mechanics (hsv//eng)

Nyckelord

Alloy 718

Anisotropy

High temperature

Hot forming

Stress relaxation

Aerospace industry

Aircraft engines

Competition

Costs

Engines

Environmental regulations

Gas emissions

Greenhouse gases

Hot stamping

Stamping

Superalloys

Advanced materials

Aero-engine structure

Anisotropic property

Lightweight components

Manufacturing process

Nickel base superalloy

Springback prediction

Stress relaxation data

Nickel alloys

Solid Mechanics

Engineering Materials

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