Abstract:Titanium bulkheads are widely used in the aviation and aerospace industry. This kind of parts are very complex, and meet high requirements for dimensional precision and the stabilization of inner quality. Some defects would be produced during the forming process, such as unfilling, overlapping, and the disturbance of forging flow line. In this paper, the effects of billet optimization and loading conditions on the forming quality during titanium alloy bulkhead isothermal closed-die forming process have been investigated, based on the rigid-viscoplastic finite element code, DEFORM-3D. The results show that the filling of die cavity can be effectively improved by using the billet with unequal thickness, which is obtained by the analysis of material flow, as a result, the dimensional precision can be satisfied for these parts. The local loading can make the deformation more uniform and eliminate the defects caused by bad material flow. The results obtained could provide a guide for proper loading scheme determining bulkhead forming