Cold forming by stretching of aeronautic sheet metal parts

http://dx.doi.org/10.1080/0951192X.2013.800641In this article, the development of an industrial prototype for manufacturing aeronautical fuselage panels is investigated. Deep drawing of large components such as aircraft fuselage panels is not an easy task in terms of dimensional accuracy, reliable material behaviour laws and failure criteria. Hot stretching processes ensure large ductility range of some materials. Nevertheless, when using high-performance aluminium alloys with acceptable low-plastic strain at ambient temperature, cold forming might be employed. A special stretching machine of 40-ton (400 kN) capability was instrumented and piloted in that way. Typical operations involved in the forming of parts are carried out with a die on which the sheet metal is successively stretched and drawn in several steps. Currently, the shape of the forming tool is directly determined from CAD models of the final sheet geometry without taking into account springback or residual effects. To increase the dimensional accuracy of the final components, a methodology to define the die shape and to control the process is proposed, taking into account the parameters influencing the forming operations. A feedback loop based on digitalised physical geometry and numerical simulation is carried out in order to ensure that the final shape of the sheet will be accurately obtained

Numerical and Experimental Analysis of Cold Stretching of Aluminum Sheets Using an Instrumented Bench

Cold stretching of a thin 5154 aluminium sheet is studied. An instrumented bench is developed to analyse the forming of double curvature panels. A numerical tool using ABAQUS software is developed to predict the behaviour of thin sheets during the stretching process and also to estimate the residual mechanical field in the formed shapes. The bench is calibrated by comparing experiments and numerical results in terms of deformed shape, in-plane strain levels and thickness evolution

Numerical and Experimental Analysis of Cold Stretching of Aluminum Sheets Using an Instrumented Bench

Cold stretching of a thin 5154 aluminium sheet is studied. An instrumented bench is developed to analyse the forming of double curvature panels. A numerical tool using ABAQUS software is developed to predict the behaviour of thin sheets during the stretching process and also to estimate the residual mechanical field in the formed shapes. The bench is calibrated by comparing experiments and numerical results in terms of deformed shape, in-plane strain levels and thickness evolution

Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes

The concept of Industry 4.0 is defined as a common term for technology and the concept of new digital tools to optimize the manufacturing process. Within this framework of modular smart factories, cyber-physical systems monitor physical processes creating a virtual copy of the physical world and making decentralized decisions. This article presents a review of the literature on virtual methods of computer-aided manufacturing processes. Numerical modeling is used to predict stress and temperature distribution, springback, material flow, and prediction of phase transformations, as well as for determining forming forces and the locations of potential wrinkling and cracking. The scope of the review has been limited to the last ten years, with an emphasis on the current state of knowledge. Intelligent production driven by the concept of Industry 4.0 and the demand for high-quality equipment in the aerospace and automotive industries forces the development of manufacturing techniques to progress towards intelligent manufacturing and ecological production. Multi-scale approaches that tend to move from macro- to micro- parameters become very important in numerical optimization programs. The software requirements for optimizing a fully coupled thermo-mechanical microstructure then increase rapidly. The highly advanced simulation programs based on our knowledge of physical and mechanical phenomena occurring in non-homogeneous materials allow a significant acceleration of the introduction of new products and the optimization of existing processes.publishedVersio

STRETCH FORMING USING HEATED DIE

The stretch forming process implies stretching and drawing into shape a sheet of material onto a die. This method is used, among other sectors, in the construction of aeroplane fuselage, as significant, complex parts can be obtained in one piece. In essence, stretch forming implies working with materials that have medium to high spring back effects, such as aluminium or magnesium alloys. Different approaches are used in manufacturing due to this phenomenon, ranging from incremental processes to multipoint dies. Another critical aspect of this process is to know how the material behaves under severe plastic deformation, as different alloys require different approaches that vary from step by step forming to in-process chemical treatments to manual pounding the metal sheet. However, all these alloys have in common that, when heated, their machinability properties improve. In this experimental study, a heated die approach was taken into consideration. 6x60 mm 100W heating elements along with temperature sensors were fitted into the die. The USB/OC326009 metal sheet is in direct contact with the die, thus assuring the heat transfer, as the temperatures reach 200 °C. The die temperature is software controlled so that maximum temperature and thermal inertia could be controlled with ease. The data indicate that this method offers significantly improved results compared to a normal room-temperature process

Pengaruh Shot Peening Terhadap Kekerasan Dan Kekasaran Produk Chemical Milling Paduan Aluminium Yang Telah Di Stretching

AbstrakPenelitian ini bertujuan untuk mengetahui pengaruh shot peening terhadap kekasaran permukaan produk pembuatan kimia Al 2524-T3 dan Al 2024-T3 yang telah diregangkan. Paduan ini direntangkan melampaui tegangan luluh, yaitu masing-masing 1%, 3% dan 5%, dan kemudian dilakukan proses penggilingan kimia di satu sisi. Etching yang digunakan dalam proses penggilingan kimia adalah larutan NaOH + Na2S + H2O dengan konsentrasi tertentu. Permukaan dilakukan proses shot peening dengan intensitas yang bervariasi masing-masing 0,03 A, 0,05 A dan 0,07 A. Bahan itu kemudian diuji kekasaran permukaan dan kekerasannya. Hasil penelitian menunjukkan bahwa kekasaran permukaan dan kekerasan material meningkat dengan meningkatnya intensitas peening. Namun, ketebalan Al 2524-T3, yang lebih tipis dari Al 2024-T3 menyebabkan tidak signifikannya proses peening shot yang diberikan pada material.. Kata kunci: Shot Peening, Chemical Milling, Kekerasan, Kekasaran Permukaan AbstractThis study aims to investigate the influence of shot peening on hardness and surface roughness of chemical mlling product Al 2524-T3 and Al 2024-T3 which have been stretched. These alloys were stretched beyond yield stress, namely 1%, 3% and 5% of each, and then performed chemical milling process of one side. The etching used in chemical milling process were NaOH+Na2S+H2O solutions with certain concentration. The surface was performed shot peening process with varying intensity of 0.03 A, 0.05 A and 0.07 A respectively. The material were then tested its surface roughness and hardness. The results show that surface roughness and hardness of material increases with the increase of peening intensity. However, the thickness of Al 2524–T3, which is thinner than Al 2024-T3 causing insignificance of the shot peening process given to the materials. Keywords: Shot Peening, Chemical Milling, Hardness, Surface Roughnes

STEM KIT: Teachers’ Notebook

info:eu-repo/semantics/publishedVersio

CONVECTIVE FLOW AND HEAT TRANSFER OF NANO-ENCAPSULATED PHASE CHANGE MATERIAL (NEPCM) DISPERSIONS ALONG A VERTICAL SURFACE

Nano-encapsulated phase change suspension is a novel type of functional fluid in which the nanoparticles undergo phase change that contribute to heat transfer. Thus, the working fluid carries heat not only by sensible heat but also in the form of latent heat stored in the particles. The natural convection and heat transfer of Nano-Encapsulated Phase Change Materials (NEPCMs) suspensions within a boundary layer along a heated flat surface are theoretically investigated in this work. The nanoparticles are core-shell structured with the core fabricated from PCMs covered by a solid shell. A similarity solution approach along with the finite element method is employed to address the phenomena. The outcomes indicate that a decisive factor in boosting the heat transfer is the temperature at which NEPCM particles undergo the phase transition. The heat transfer parameter can be enhanced by about 25% by just adding 5% of NEPCM particles, compared to the case with no NEPCM particles

Explosive forming of 2219 aluminum final report

Variables affecting metal springback of aluminum during explosive deformation and influence of high energy forming on metallurgical behavio