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Virtual titanium fabrication - mechanical cutting and forming including demonstrator

Published: 16 February 2015

In order to improve the competitiveness the Swedish aero engine industry offers fabrication as a method for manufacturing of static load carrying structures in aero engines. Fabrication involves material forms such as forgings, metal sheets and castings, which can be mechanically cut before joined together by welding. This manufacturing method enables a flexible design and manufacturing route which are important pre-requisites for light weight design that could render in reduced fuel consumption (CO2) and product cost. During the welding procedure part geometries can change because of internal residual stresses. These geometrical changes are important to be able to predict with high accuracy through the manufacturing processes using Finite Element analysis (FE), in order for fabrication methods to be robust and applicable. To enable efficient compensation of forming tools and welding processes for such geometrical changes, research activities are needed, and development, of processes including cutting and hot forming of titanium. These processes can thereafter become connected parts of a virtual manufacturing chain.

This project will result in FEM and PFEM-models for analysis with high accuracy enabling manufacturing by using virtual schemes. In addition, the aim is to support a Swedish SME with experience of cutting and forming of advanced materials, and with high ambitions to develop these processes further for product and process development. The project gathers competence from Swedish aero engine industry.

The objectives of the project are:

  • Further development of FEM and PFEM methodology and thermo-mechanical material characterization of titanium machining and thermoforming. Simulation Driven Development of strategies for processing such as turning and shaping that evaluates different methods to ensure the geometry, material properties and surface structure of the produced component and throughout the entire manufacturing chain.


  • Tight tolerance requirements means that the residual stress state and form deviations studied by advanced methods for FE analysis that aims to provide results to the analysis of subsequent fabrication steps of the aerospace industry. Two prototype components manufactured by the respective machining and thermoforming and evaluated.


Project Manager: Eva-Lis Odenberger , LTU Senior Lecturer, Adjunct


Researchers: Par Jonsén and Ales Svoboda

Project funding: