In order to integrally manufacture the large TC4 titanium alloy part, an electrically-assisted incremental forming process is cleverly proposed to solve the traditional hot forming disadvantages of expensive heating furnaces and long cycle period. The two-step simulation method including thermal-electricity coupling simulation and thermo-mechanical coupling simulation was selected to predict the temperature variations and the sheet deformation behaviors. The electrically-assisted incremental forming experiment of thin TC4 titanium alloy sheet was performed. The highest prediction error is 6% for springback angles. The thrice forming at 10.9 A/mm2 satisfies the precision requirement of the designed part. Therefore, the two-step simulation method can effectively calculate the electrically-assisted incremental process. The electrically-assisted incremental forming technique is very promising for the integral producing large titanium alloy part.
Keywords: electrically-assisted incremental forming; springback; thin TC4 titanium alloy sheet; two-step simulation method.