TWISTER: Titanium Wire for Inovative Spring Technologies and Emissions Reduction

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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.