Numerical simulation and experimental study of hot-spinning damage characteristics of TC4 titanium alloy tube

The inadequate selection of spinning process parameters renders the titanium alloy tube susceptible to cracking or fracturing during the spinning process, thus necessitating an immediate investigation into the phenomena of tube cracking within the spinning molding process. A finite element model of a spinning ball was developed using Abaqus finite element software, grounded in the Johnson-Cook damage model. The model’s validity was confirmed, and variations in damage values across different process parameters were examined, alongside the influence of equivalent plastic strain and stress triaxiality on damage accumulation. Response surface approach was employed to optimize the parameters of the spinning process, followed by finite element simulation and experimental validation with the modified parameters. The findings indicate that the developed finite element model is effective; during the spinning process, the tube’s outer surface is most susceptible to preferential fracture, and the damage value varies according to different process parameters, demonstrating a direct correlation with the feed rate and thinning rate, while exhibiting an inverse correlation with temperature. The ideal combination of spinning process parameters was determined using the response surface methodology: spinning temperature of 671°C, feed rate of 0.1 mm/r, and thinning rate of 26%.