Numerical and Experimental Investigation of the Innovatory Incremental-Forming Process Dedicated to the Aerospace Industry

Abstract

The main goal of this work is development of the incremental-forming (IF) process for manufacturing integral elements applicable to the aerospace industry. A description of the proposed incremental-forming concept based on division of large die into a series of small anvils pressed into the material by a moving roll is presented within this article. A unique laboratory device has been developed to investigate the effects of process parameters on the material flow and the press loads. Additionally, a developed numerical model of this process with specific boundary conditions is also presented and validated to prove its predictive capabilities. However, main attention is placed on development of the process window. Thus, detailed investigation of the process parameters that can influence material behavior during plastic deformation, namely, roll size and roll frequency, is presented. Proper understanding of the material flow to improve the IF process, as well as press prototype, and to increase its technological readiness is the goal of this article. Results in the form of, e.g., strain distribution or recorded forging loads are presented and discussed.

Study of the Strain Resistance During the Tests of the Wheel Steel

“…The orthogonality of the central compositional plan is provided by the appropriate selection of the star shoulder α (for three factors α = 1,215) and special transformation of Cn; S, P< 0.04. [14].…”

Evaluation of Local Material Flow during Complex Deformation Conditions on the Basis of Multi Scale Analysis

“…machining, rolling, extrusion or casting as seen in Figure 1. Unfortunately, most of them are connected with high manufacturing costs and technical problems, small efficiency or limited applications [1,2]. It seems, that the best solution is to use forging methods, which provide a possibility to control microstructure evolution during forming and as a result provides a possibility to reduce final weight of the product while maintaining its strength properties.…”