Isothermal flashless die forging process of Ti - alloy structural air - frame part with varying thickness rib has been modelled in this paper.The results of present study show that a upside - down trapezoid rib would be formed and buckling would occure as blank is reduced,if the thickness of billet is maller than or equal to the thickness of rib. During modelling process of structural air frame part with E type cross - section rib, the saddle or lap would be formed finally at the middle of transverse rib between ribs with increase in deformation.If metal is allowed to flow out at confluence of longitudinal and transverse rib, the lop defect would be eliminated,, but a pipe cavity is obvious on corresponding loca- tion of blank. of defect formation depends on distance of metal flow ,friction,temperature homoge- neity of the blank and complexity of the part.
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