Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

The cross wedge rolling (CWR) deformation and fracture of a Ti6Al4Al (ELI) alloy were investigated experimentally and numerically using a coupled thermo-mechanical finite element model analysis. The experimentally determined flow stress and damage model parameters were verified by tension split Hopkinson pressure bar testing of notched samples. The simulation and experimental CWR forces showed well agreements except near the end of the stretching zone. The model analysis showed that the temperature distribution in the work piece was non-uniform during the CWR. When the initial temperature of the work piece was relatively low, the work piece temperature increased, a heating effect of the plastic deformation, while relatively high initial work piece temperatures resulted in cooling the work piece, caused by the work piece contact with the tools. The cracks were shown numerically to initiate in the midsections of the work piece during the guiding action and elongated in a direction normal to the maximum tensile stress triaxiality, resulting in cruciform-shaped crack formation, which was well agreed with the previously observed crack shape.

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