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  • 1.
    Pérez Caro, Lluís
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. RISE IVF AB.
    Odenberger, Eva-Lis
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. RISE IVF AB.
    Schill, Mikael
    DYNAmore Nordic AB.
    Steffenburg-Nordenström, Joachim
    GKN Aerospace Sweden AB.
    Niklasson, Fredrik
    GKN Aerospace Sweden AB.
    Oldenburg, Mats
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Prediction of shape distortions during forming and welding in alloy 718Manuscript (preprint) (Other academic)
    Abstract [en]

    The finite-element method (FEM) has considerably contributed to the development of more advanced manufacturing methods for metal structures. The prediction of the final shape of a component is of great interest to the manufacturing industry. In addition to its inherent difficulties, the presence of various types of processes in the manufacturing chain may dramatically increase the level of demand. Therefore, including all steps of the manufacturing process in the simulations is key to being successful. This has been done for a long time in the stamping industry, which involves sequences of forming, trimming, and springback. However, more complex manufacturing procedures, that include assembling of formed parts with forgings and castings via welding, have been modeled with simplifications, resulting in a reduced prediction accuracy. This hinders the compensation of accumulated shape distortions based on the 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 the present study, a double-shaped part manufactured from alloy 718 is formed at 20 °C and laser-welded using the bead-on-plate procedure. The coupling of different manufacturing analyses, including cold forming, trimming, result mapping, welding, cooling, and springback, is achieved using LS-DYNA. Additionally, the effect of adding the GISSMO damage model in the forming simulation is studied. The results of the forming analysis are used as inputs for the material model *MAT_CWM in the welding simulation. The anisotropic thermomechanical properties of alloy 718 are determined at temperatures up to 1000 °C. Encouraging agreement is found between the model predictions and the results of forming and welding tests. The findings underscore the importance of including the material history and accurate process conditions along the manufacturing chain to both the prediction accuracy of shape distortions, and to the potential of the industry.

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