Comparative Analysis of Finite Element Formulations for Simulating Hot Forming of Ti-6Al-4V Aerospace Components

Abstract

This study presents a comprehensive finite element analysis to compare the performance of different element formulations (classic shell elements, solid elements, and continuum shell elements) in simulating the hot-forming process at 725 °C of a complex Ti-6Al-4V aerospace component with an initial blank thickness of 1.6 mm (0.063 inches). The Ti-6Al-4V blank is modeled as a deformable body exhibiting anisotropic plastic behavior, whereas the forming tools (matrix and punch) are assumed to be rigid bodies. The simulation accounts for temperature and strain rate effects on the material properties, incorporating phenomena such as friction and anisotropy. Three different element types are studied and compared: S4R and S4 (classic shells), C3D8R and C3D8 (solids), and SC8R (continuum shell with reduced integration). Finally, the model is validated by comparing the predicted final part geometry, especially the thickness distribution, against the experimental measurements. The model can also predict the springback effect on the final geometry. The SC8R continuum shell element provides the smoothest representation of thickness variations along critical regions of the final part. The study highlights the importance of selecting the appropriate element type for the accurate simulation of hot-forming processes involving large deformations and complex contact conditions. The ability of continuum shell elements to accurately capture the thickness variations makes them an ideal candidate for such applications.