Investigation on mechanism in fabricating truncated cone with tooth features of titanium alloy via flexible free incremental forming at room temperature.

It has been a challenge to efficiently make titanium alloy thin-walled components by sheet metal forming. Incremental sheet forming (ISF) method provides a promising way to increase the formability of low-ductility metallic sheets, but making titanium alloy sheet panels still needs heating by electricity or laser. The present work investigates the deformation mechanism in fabricating truncated cones of titanium alloy with tooth features realized by flexible free incremental sheet forming (FFISF) at room temperature. Experimental investigations on auxiliary sheets and tool path selections, analytical modeling, finite element simulation, and microstructure characterization have been conducted to evaluate the deformation mechanism in terms of the geometric deviation, thickness distribution and microstructure evolution of TA2 and TC4. Results indicate that the I-O loading path coupled with an optimized auxiliary sheets selection can ensure the successful fabrication of designed panel without defects. An analytical model is proposed to predict the free edge dependent law of thickness distribution in FFISF, indicating the material thinning is positively correlated with the distance from the free edge, while the thinning rate is inversely proportional to the yield strength. A more uniform thickness of TC4 panel is obtained compared with TA2. Finally, the improved formability of titanium alloys by FFISF can be attributed to grain subdivision, decreasing of intragranular deformation, and optimization of dislocation movement. [Display omitted] • Obtained truncated cone with tooth features of titanium alloy by FFISF at room temperature. • Determined optimal process set with feasible auxiliary sheet set and I-O loading path. • Found out free edge dependent thickness distribution against Cosine law. • Revealed homogenous deformation with less intragranular deformation for improved formability. [ABSTRACT FROM AUTHOR]