Forming Process for Titanium Alloy Honeycomb Corrugated Sheet

Two forming gears were used for roll mold and another tooth profile mould which is exactly the same as that of corrugated sheet in design parameters was used for sizing. Titanium alloy corrugated sheet was manufactured by the composited process of roll forming and sizing. Through Ansys/Ls-Dyna software, finite element modeling of the forming process was performed to analyze the relationship between gear clearance and quality of corrugated sheet. And then, the experimentation was carried out to validate reliability of the composited process. The results show that, it was feasible to fabricate the corrugated sheet with high precision by this composited process, the maximum value of dimension error was only 1.8%. Furthermore, maximum value of gear clearance were one of the key factors affecting the quality of corrugated sheet, the optimized values were maximum value of gear clearance of 0.2 mm, sizing stress of 3 000 MPa and sizing time of 30 s. It′s also found that it can highly reduce the accuracy requirement of manufacturing and assembly by using adjustable body to control parallelism and maximum value of gear clearance.