Examining the functional feasibility of an electrically actuated SPF machine

An innovative mobile scale superplastic forming (SPF) machine was designed by Aerospace Cutting Tool ltd (ACT) to form small size parts from metal sheets via an electrically actuated SPF machine. This paper presents finite element analysis conducted in PamStamp to investigate the capabilities and limitations of the machine. Material card for Ti-6Al-4V sheet was implemented in the numerical simulations for this purpose. Krupkowski hardening law is utilised for stress flow definition. The die and, consequently, the blank were designed based on the dimensions of tool platform area and the capabilities of the machine. A die with an elliptical shape cavity was considered for the simulations. The outcomes of the simulations were collected for thinning of the sheet, level of part formation, applied pressure cycle, and the required applied forming force. The optimised model to perform future SPF trial was justified by the reaction force developed on the die due to the forming pressure cycle. The numerical simulation results suggest the optimal trial to examine the functionality of the new electrically actuated SPF machine.