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Modeling and validation of a forming and welding procedure in alloy 718
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. Swerea IVF AB. (Solid Mechanics)ORCID iD: 0000-0002-1432-444X
(English)Manuscript (preprint) (Other academic)
Abstract [en]

The Finite ElementMethod (FE) has enabled important advances in the study and design ofcompetitive manufacturing procedures for metal structures. Predicting the final geometry of a component is a major issue to the manufacturing industry. This is a complex task, especially if the manufacturing involves several types of processes. In order to succeed, the complete manufacturing process chain has to be included in the simulation. This has been done for quite some time in the stamping industry involving sequences of trimming, forming and springback. However, more complex manufacturing procedures that include assembling of formed parts with forgings and castings by welding have been modeled with simplifications limiting prediction accuracy and thereby hindering compensation of accumulated shape distortions based on simulation results. One such example is the fabrication of aero engine structures in which the history from the forming procedure has not been considered in subsequent welding and heat treatment analyses. In this work, coupling of different manufacturing analyses is done using LS-DYNA including cold forming, trimming, result mapping, welding, cooling and springback. The results from the forming analysis are used as input to the welding simulation, performed using the novel material model *MAT_CWM. The anisotropic thermo-mechanical properties of alloy 718 are determined and included at temperatures up to 1000˚C. Comparison of model predictions with forming and welding tests show encouraging agreement. Our findings underscore the importance of including the history and accurate process conditions along the manufacturing chain to the prediction accuracy of shape distortions and the potential to the industry.

Keyword [en]
alloy 718, forming, welding, springback, nickel-based superalloys, superalloys
National Category
Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials Applied Mechanics
Research subject
Solid Mechanics
Identifiers
URN: urn:nbn:se:ltu:diva-63348OAI: oai:DiVA.org:ltu-63348DiVA: diva2:1095444
Projects
NFFP6 - Virtuell processkedja för plåtformade flygmotorstrukturer i superlegeringar – Validering och demonstrator
Funder
VINNOVA, 2013-01173
Available from: 2017-05-14 Created: 2017-05-14 Last updated: 2017-05-14

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CiteExportLink to record
Permanent link

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Cite
Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
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  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf