TWISTER: Titanium Wire for Inovative Spring Technologies and Emissions Reduction

谢菲尔德大学对“创新弹簧技术和减少排放的钛丝（TWISTER）”项目的贡献将是开发和验证连续挤压机的最佳工具和工艺参数，以及设计用于高性能弹簧和弹簧制造工艺路线的钛丝生产的最佳拉丝和热处理时间表。UOS还将通过金相学和有限元建模支持下游弹簧设计和制造中的开发。这将由杰克逊博士和一名博士后研究助理进行。因此，该项目的目标在其最广泛的意义上是：开发一种新的挤压和冷拉工艺路线，用于生产钛丝，用于汽车行业的气门和悬架弹簧制造。工作包1：连续旋转挤压（CRE）工具寿命评估（UOS和Meltech）：这包括通过有限元建模（和专业知识）设计工具，然后与Meltech合作确定连续挤压过程中不同钛颗粒形态和化学成分的工具磨损率，生产率为每分钟5米。从这样的工作，工艺路线的生产率为不同的颗粒和化学品，包括加工屑，商业钛粉和新兴的低成本合金粉末将创建。工作包2：拉丝优化（UOS）：这个工作包将使用变形有限元建模软件，以确定最佳的冷拉时间表和模具设计的下游弹簧原料。据设想，连续挤压材料将需要最少的冷拉相比，传统生产的电线，但这个工作包将加速优化模具设计和通过时间表，包括任何intermediateannealing阶段。工作包3：弹簧设计和制造（高性能弹簧和UOS）：这将包括分别为Bentley和K-Tech悬架设计和制造气门弹簧和悬架弹簧。UOS将通过使用DEFORM和工作包1和2的输出来支持高性能弹簧，以模拟CNC卷绕操作。UOS还将对支持高性能弹簧初步开发的弹簧产品进行金相和测试。工作包4：机械测试和验证（Performance Springs、Bentley、K-Tech和UOS）：该工作包将侧重于整个项目中产生的钢丝和弹簧产品的机械测试（静态和动态测试）。最佳的弹簧设计将在与最终用户Bentley和K-Tech合作的悬架布置和发动机测试中进行测试。

The contribution from the University of Sheffield to the "Titanium Wire for Inovative Spring Technologies and EmissionsReduction (TWISTER)" project will be on the development and validation of optimum tooling and process parameters forthe continuous extrusion machine and the designing of optimum wiredrawing and heat treatment schedules for subsequentwire production that will feed into Performance Springs and the springmaking process routes. The UOS will also supportthe developed in the downstream spring design and manufacture through metallography and finite element modelling. Thiswill be undertaken by Dr Jackson and a Postdoctoral Research Associate. Thus the aim of the project in its broadest senseis: Development of a novel extrusion and cold drawing process route for the production of titanium wire for subsequentvalve and suspension spring manufacturing for the automotive sector. This will be achieved by the following four workpackages.Work Package 1: CONTINUOUS ROTARY EXTRUSION (CRE) TOOL LIFE ASSESSMENT (UOS and Meltech): Thisincludes design of tooling through finite element modelling (and know how) and then in collaboration with Meltechdetermining tooling wear rates during continuous extrusion for different titanium particulate morphologies and chemistriesfor production rates in the order of 5 metres per minute. From such work, process maps of wire production rates fordifferent particulate and chemistries; including machined swarf, commercial titanium powder and emergent novel low costalloy powder will be created.Work Package 2: WIRE-DRAWING OPTIMISATION (UOS): This work package will use DEFORM finite element modellingsoftware to determine of the optimum cold drawing schedule and die design for downstream spring feedstock. It isenvisaged that the continuous extruded material will need minimal cold drawing compared to conventionally produced wire,but this work package will acceletrate the optimisation of the die design and pass schedule, including any intermediateannealing stages. Cold drawing schedules will be deisgned for each particulate feedstock.Work Package 3: SPRING DESIGN & MANUFACTURE (Performance Springs and UOS): This will include the design andmanufacture of valve and suspension springs for Bentley and K-Tech Suspensions respectively. UOS will supportPerformance Springs by using DEFORM and outputs from work packages 1 and 2 to model the CNC coiling operation.UOS will also conduct metallography and testing of spring product supporting Performance Springs primary development.Work Package 4: MECHANICAL TESTING & VALIDATION (Performance Springs, Bentley, K-Tech and UOS): This workpackage will focus on the mechanical testing (both static and dynamic testing) of both wire and spring product generatedthroughout the programme. Optimum spring designs will be tested in suspension arrangements and engine tests incollaboration with the end users Bentley and K-Tech.