TY - JOUR
T1 - Design of an innovative multi-stage forming process for a complex aeronautical thin-walled part with very small radii
AU - Wang, Yao
AU - Lang, Lihui
AU - Sherkatghanad, Ehsan
AU - Nielsen, Karl Brian
AU - Zhang, Chun
PY - 2018/11/1
Y1 - 2018/11/1
N2 - In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in one stage. Therefore, an innovative multi-stage active hydroforming process assisted by the rigid forming method was designed. In addition, an optimized blank geometry is obtained. In fact, the main focused point of this paper is to propose a new small radius rounded corner forming technique and analyze the mechanism. Two kinds of forming modes of changing a big rounded corner into a small one, which are related to different tangential positions of the die in the process of calibration, are analyzed theoretically. Meanwhile, the stress and strain states of the deformation region are compared. The relationships between the minimum relative radii of rounded corners I and II in the first stage and the hydraulic pressure are calculated by the bending theory. Finally, the influences of the tensile-bulging effect and the interface condition of the double-layer sheet on the forming quality of the specimen are investigated. The achieved results can make a foundation for utilizing the proposed method in forming of thin-walled parts with very small radii.
AB - In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in one stage. Therefore, an innovative multi-stage active hydroforming process assisted by the rigid forming method was designed. In addition, an optimized blank geometry is obtained. In fact, the main focused point of this paper is to propose a new small radius rounded corner forming technique and analyze the mechanism. Two kinds of forming modes of changing a big rounded corner into a small one, which are related to different tangential positions of the die in the process of calibration, are analyzed theoretically. Meanwhile, the stress and strain states of the deformation region are compared. The relationships between the minimum relative radii of rounded corners I and II in the first stage and the hydraulic pressure are calculated by the bending theory. Finally, the influences of the tensile-bulging effect and the interface condition of the double-layer sheet on the forming quality of the specimen are investigated. The achieved results can make a foundation for utilizing the proposed method in forming of thin-walled parts with very small radii.
KW - Double-layer sheet
KW - Hydroforming
KW - Multi-stage forming
KW - Small rounded corner
KW - Tensile-bulging effect
UR - http://www.scopus.com/inward/record.url?scp=85042068459&partnerID=8YFLogxK
U2 - 10.1016/j.cja.2018.01.019
DO - 10.1016/j.cja.2018.01.019
M3 - Journal article
SN - 1000-9361
VL - 31
SP - 2165
EP - 2175
JO - Chinese Journal of Aeronautics
JF - Chinese Journal of Aeronautics
IS - 11
ER -