TWISTER: Titanium Wire for Inovative Spring Technologies and Emissions Reduction

谢菲尔德大学对“用于创新弹簧技术和排放的钛丝还原(扭线机)”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，以及为后续钢丝生产设计最佳的拉丝和热处理计划，这些计划将提供给性能弹簧和弹簧制造工艺路线。UOS还将通过金相和有限元建模支持下游弹簧设计和制造方面的开发。这项工作将由杰克逊博士和一名博士后研究助理承担。因此，该项目最广泛的目标是：开发一种新的挤压和冷拔工艺路线，用于生产随后用于汽车行业的阀门和悬挂弹簧制造所需的钛丝。这将通过以下四个工作包实现。工作包1：连续旋转挤压(CRE)刀具寿命评估(UOS和Meltech)：这包括通过有限元建模(和技术诀窍)设计模具，然后与Meltech合作，确定连续挤压过程中不同钛颗粒形貌和化学物质的刀具磨损率，生产率约为每分钟5米。工作包2：拉丝优化(UOS)：此工作包将使用DEFORM有限元建模软件来确定下游弹簧喂料的最佳冷拔规程和模具设计。据设想，与传统生产的线材相比，连续挤压材料只需要最少的冷拔，但该工作包将加速模具设计和道次计划的优化，包括任何中间的退火阶段。工作包3：弹簧设计和制造(Performance Springs和UOS)：这将包括分别用于宾利和K-Tech悬架的阀门和悬挂弹簧的设计和制造。UOS将通过使用Deform和工作包1和2的输出来模拟数控卷绕操作来支持Performance Springs。UOS还将对支持Performance Springs初级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、宾利、K-Tech和UOS)：该工作包将重点放在整个计划中产生的钢丝和弹簧产品的机械测试(静态和动态测试)上。最优的弹簧设计将在悬架布置和发动机测试中与最终用户宾利和K-Tech合作进行测试。

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.