Developing a digital twin for next generation forging of high-value titanium alloy components

开发用于下一代高价值钛合金部件锻造的数字孪生

• 批准号: 2665415
• 金额: --
• 依托单位: University of Strathclyde
• 依托单位国家: 英国
• 项目类别: Studentship
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=studentship-2665415
• 关键词: Developing; digital; twin; next; generation

The goal of the project is to develop a digital twin of state-of-the-art open and closed die hot forging processes used for manufacturing high-performance titanium alloy components. This will be achieved by developing novel experimentally informed multi-scale materials simulations to build up forging behaviour maps as a function of the manufacturing variables. Property-determining microscopic changes will be evaluated using physics-based phase field models, which will feed local material property data into global finite-element models of component forging. The structural integrity of titanium alloys is especially sensitive to variations in the microstructure. Components are typically closed die forged from sections of larger billets, and the billets are shaped from cast ingots using a series of open die forging steps. Open die forging is needed to break up the coarse microstructure of the precursor ingots, which themselves are produced using a sequence of several melting and re-solidification steps to increase their purity and homogeneity. Any non-uniformities and defects retained from the earlier stages are most often inherited throughout the subsequent steps in the long processing sequence. Furthermore, achieving a high degree of microstructural control becomes progressively more difficult as manufacturers try to forge larger components, due to existing stress and temperature gradients and residual stresses. As much as 70% of material must be machined away due to microstructural inconsistencies, requiring billets to be considerably larger than the final parts. Furthermore, to allow for possible microstructural inconsistencies, components may be manufactured to satisfy more conservative safety margins and simpler geometries, which increases their weight. This is a clear detriment to fuel efficiency for the aerospace manufacturers - which are major users of titanium forgings. To solve these challenges, it is essential that the component-scale deformation models used by the digital twin reflect the microstructural sensitivity of real titanium alloys. The following tasks will form the main objectives of the project: development of novel phase field models that can accurately replicate the property-controlling microstructural transformations in titanium alloys during hot forging development of a specialised modelling algorithm that will link the concurrent microscopic and component scale models. The algorithms will be responsible for the exchange of property and deformation condition data between the phase field and finite element models respectively, as well as the generation and administration of the necessary RVEs validation of the new models as a framework for the digital twin. This will involve the simulation of suitable open and/or closed die forging of real components over a range of processing conditions. This will be used to map out the microscopic and macroscopic properties of the final product as a function of the various process parameters. Such maps would then be suitable for informing manufacturers regarding the optimal hot- deformation conditions and troubleshooting the forging sequences, as well as effectively optimising the component geometries as new technological capabilities emerge.

该项目的目的是开发用于制造高性能钛合金组件的最先进和封闭的开放和封闭的死亡热锻造过程。这将通过开发新颖的实验知识的多尺度材料模拟来实现，以构建锻造行为图作为制造变量的函数。属性确定的微观变化将使用基于物理的相位场模型进行评估，该模型将将本地材料属性数据馈送到组件锻造的全局有限元模型中。钛合金的结构完整性对微观结构的变化特别敏感。组件通常是从较大的方块的部分中闭合的伪造，并且使用一系列开放的模具锻造步骤从铸锭中形成了钢筋。需要开放的锻造才能打破前体挖掘机的粗大微结构，这些微观结构本身是使用几个熔化和重新固定步骤来提高其纯度和同质性的序列生产的。从早期阶段保留的任何非均匀性和缺陷最常见于长期处理顺序的随后步骤中。此外，由于现有的压力和温度梯度和残留应力，因此，随着制造商试图制造较大组件的高度逐渐变得更加困难。由于显微结构上的不一致，必须将多达70％的材料加工，这要求钢坯比最终部分大得多。此外，为了允许可能的显微结构不一致，可以制造组件以满足更保守的安全边缘和更简单的几何形状，从而增加其体重。对于航空航天制造商来说，这显然是损害燃油效率的损害，这是钛合金的主要用户。为了解决这些挑战，数字双胞胎使用的组件尺度变形模型至关重要。以下任务将构成项目的主要目标：开发新型相位场模型，这些模型可以准确地复制钛合金的属性控制的微观结构转换在热锻造开发的专用建模算法的过程中，该算法将链接并发的显微镜和组件量表模型。该算法将分别在相位字段和有限元模型之间分别交换属性和变形条件数据，以及新模型的必要RVE验证的生成和管理，作为数字双胞胎的框架。这将涉及在一系列处理条件下对实际组件的合适开放和/或封闭的伪造模拟。这将用于绘制最终产品的显微镜和宏观特性作为各种过程参数的函数。然后，此类地图将适合告知制造商有关最佳的热变形条件和对锻造序列进行故障排除，并有效地优化组件的几何形状，因为新技术能力出现。