Dynamic distortion measurements during laser forming of Ti’6Al’4V and their comparison with a finite element model

Author:

Reeves M1,Moore A J1,Hand D P1,Jones J D C1,Cho J R2,Reed R C3,Edwardson S P4,Dearden G4,French P4,Watkins K G4

Affiliation:

1. Heriot-Watt University School of Engineering and Physical Sciences, Department of Mechanical Engineering Edinburgh, Scotland, UK

2. University of Cambridge Rolls-Royce Ni-base UTC, Department of Materials Science and Metallurgy UK

3. University of British Columbia Department of Metals and Materials Engineering Vancouver, British Columbia, Canada

4. University of Liverpool Laser Group, Department of Engineering UK

Abstract

Laser forming is, potentially, an attractive flexible manufacturing technique for the controlled forming of aerospace alloys. Laser forming experiments using a continuous-wave CO2 laser were performed on coupons of material 80 mm × 80mm in area and 2mm thick, with sequential passes of the laser beam, at a surface scanning rate of 20 mm/s with 90 s of convective cooling between passes. A novel surface profilometer that was specifically developed to operate under the conditions of high vibration and stray light typically found in laser machining applications recorded transient surface shape changes during individual laser passes at frame rates of 4 and 0.2 Hz. A finite element model was developed using ABAQUS for the laser forming of linear bends in free Ti-6A1-4V sheets, with sequentially coupled thermal and elastic-plastic analysis incorporating temperature-dependent material properties. Transient heat source scanning was implemented to simulate the experiment. Good agreement was found between the experimental three-dimensional shape data and those predicted by the transient model. In particular, the formation of an unwanted ‘camber’ distortion perpendicular to the desired main bend was correctly predicted; its magnitude and temporal evolution throughout the three laser passes, and during the periods of convective cooling, agreed well with the experimental data. The model and the shape measurement technique will enable the future predictive controlled laser forming of more complex three-dimensional shapes.

Publisher

SAGE Publications

Subject

Industrial and Manufacturing Engineering,Mechanical Engineering

Cited by 17 articles. 订阅此论文施引文献 订阅此论文施引文献,注册后可以免费订阅5篇论文的施引文献,订阅后可以查看论文全部施引文献

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