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<p>Electrically assisted forming (EAF) offers significant advantages for processing difficult-to-form metals like titanium alloys, particularly by reducing flow stress, improving formability, and minimizing springback. This study investigates the combination of EAF with the stretch-bending process as a viable alternative to traditional hot-forming techniques for precisely shaping TC4 titanium alloy bending components. Controlling springback is a critical challenge in the stretch-bending process. An electro-thermal–mechanical coupling constitutive model was developed based on the Johnson–Cook model, incorporating the effects of temperature and current density. This constitutive model can well reflect the stress–strain relationship of TC4 titanium alloy material. The UHARD subroutine was employed for the secondary development of this constitutive model, and simulations of the electrically assisted stretch-bending process were conducted. The effects of parameters such as pulse current density, pre-tension stress, and bending radius on springback were studied. Physical experimental validation confirms the accuracy of the finite element model within a 5% error.</p>

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Springback prediction and control of TC4 titanium alloy electrically assisted stretch-bending based on electro-thermal–mechanical coupling constitutive model

  • 期刊论文

  • 发表日期：

    2025年6月23日

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  • Zheng Qiao,
  • Ruixue Zhai,
  • Lujia Tian,
  • Zhenhai Yu,
  • Shangwu Jia,
  • Qingdang Meng

摘要

Electrically assisted forming (EAF) offers significant advantages for processing difficult-to-form metals like titanium alloys, particularly by reducing flow stress, improving formability, and minimizing springback. This study investigates the combination of EAF with the stretch-bending process as a viable alternative to traditional hot-forming techniques for precisely shaping TC4 titanium alloy bending components. Controlling springback is a critical challenge in the stretch-bending process. An electro-thermal–mechanical coupling constitutive model was developed based on the Johnson–Cook model, incorporating the effects of temperature and current density. This constitutive model can well reflect the stress–strain relationship of TC4 titanium alloy material. The UHARD subroutine was employed for the secondary development of this constitutive model, and simulations of the electrically assisted stretch-bending process were conducted. The effects of parameters such as pulse current density, pre-tension stress, and bending radius on springback were studied. Physical experimental validation confirms the accuracy of the finite element model within a 5% error.