A pathway to refined stress and strain distributions in aerospace-grade Ti/Al bi-metal sheets: Synergizing theoretical insights and FEM simulations

This study introduces an innovative theoretical model critical for predicting stress and strain distributions in Ti/Al bi-metal sheet production and its subsequent deep drawing process. Grounded in extensive mechanical and geometric analysis, the model facilitates manufacturing process optimization and the production of high-quality components. Finite Element Method (FEM) simulations are integrated to examine the significant effects of die geometric parameters on metal flow dynamics and susceptibility to material stress. The model’s precision is enhanced by incorporating anisotropic material properties and cohesive zone models. A rigorous experimental framework validates the model, highlighting the practical utility of optimized parameters in Ti/Al bi-metal component fabrication. Additionally, uniaxial tensile tests using the Video Image Correlation-3D (VIC-3D) system provide detailed insights into material deformation, elucidating stress distribution and metal flow in composite layers. Thus, the research presents a refined methodology for the efficient production of Ti/Al bi-metal components, offering valuable knowledge transferable to various materials and processing scenarios. The findings of this work are expected to make a significant impact on material engineering and mechanical manufacturing.