Simulation of sheet-titanium forming of welded blanks

The increase in demand for the light and tough drawn-parts causes the growing interest in sheet metal forming of Tailor-Welded Blanks (TWB). Application of such blanks allows for achieving in one operation the drawn-parts characterized by diverse strength and functional properties. It also allows for reduction of material waste and decrease in number of parts needed to produce component. Weight reduction is especially important for the car and aircraft industry. Forming welded blanks requires solving many problems such as different plasticity of the joined materials, presence of the weld and its dislocation. In order to evaluate suitability of welded blanks for the forming processes, it is necessary to carry out several studies, including numerical simulations of the process, that will allow for prediction of sheet behaviour in consecutive forming stages. Although to date aluminium and steel TWBs are mainly used, the aircraft industry is also interested in application of titanium TWBs. Generally sheet-titanium forming is more difficult than steel or aluminium sheets. The weld presence complicates the forming process additionally. In the paper some numerical simulation results of sheet-titanium forming of welded blanks will be presented. Forming the spherical caps from the uniform and welded blanks will be analysed. Grade 2 and Grade 5 (Ti6Al4V) titanium sheets with thickness of 0.8 mm will be examined. A three-dimensional model of the forming process and numerical simulation will be performed using the ADINA System v.8.6, based on the finite element method (FEM). An analysis of the mechanical properties and geometrical parameters of the weld and heat affected zone (HAZ) are based on the experimental studies. Drawability and possibilities of plastic deformation will be assessed basing on the comparative analysis of the determined plastic strain distributions in the drawn-parts material and thickness changes of the drawn-part wall. The results obtained in the numerical simulations will provide important information about the process course. They will be useful in design and optimization of the forming process