Prediction of stiffener buckling in press bend forming of integral panels

In order to predict the buckling of stiffeners in the press bend forming of the integral panel,a method for solving the critical buckling load of the stiffeners in press bend forming process was proposed based on energy method,elastic-plastic mechanics and numerical analysis.Bend to buckle experiments were carried out on the designed press bend dies.It is found that the predicted results based on the proposed method agree well with the experimental results.With the proposed method,the buckling of the stiffeners in press bend forming of the aluminum alloy integral panels with high-stiffener can be predicted reasonably.

FEM Analysis and Simulation for Prediction of Press-Forming and Spring Back of Spiral Plates

In order to provide technical supports for designing a new type of spiral plate forming machine, FEM analysis and simulation were carried out based on pressing tests. Deformation, stress distribution, residual stress and spring back of the spiral plate were calculated. Relationships between the spiral pitch to inclination angle of the punch and die, material properties and thickness of the plate were analyzed. A data converter was developed and effectively used in the analysis. The results of FEM analysis and simulation have been applied to design the spiral plate forming machines.

Optimization of press bend forming path of aircraft integral panel

In order to design the press bend forming path of aircraft integral panels,a novel optimization method was proposed, which integrates FEM equivalent model based on previous study,the artificial neural network response surface,and the genetic algorithm.First,a multi-step press bend forming FEM equivalent model was established,with which the FEM experiments designed with Taguchi method were performed.Then,the BP neural network response surface was developed with the sample data from the FEM experiments.Furthermore,genetic algorithm was applied with the neural network response surface as the objective function. Finally,verification was carried out on a simple curvature grid-type stiffened panel.The forming error of the panel formed with the optimal path is only 0.098 39 and the calculating efficiency has been improved by 77%.Therefore,this novel optimization method is quite efficient and indispensable for the press bend forming path designing.

Forming-Precision-Driven Structure Design of Hydraulic Press: Methodology and Case Study

The structure stiffness of presses has great effects on the forming precision of workpieces, especially in near-net or net shape forming. Conventionally the stiffness specification of presses is empirically determined, resulting in poor designs with insufficient or over sufficient stiffness of press structures. In this paper, an approach for the structure design of hydraulic presses is proposed, which is forming-precision-driven and can make presses costeffective by lightweight optimization. The approach consists of five steps:(1)the determination of the press stiffness specification in terms of the forming precision requirement of workpieces;(2)the conceptual design of the press structures according to the stiffness and workspace specifications, and the structure configuration of the press;(3)the prototype design of the press structures by equivalently converting the conceptual design to prototypes;(4)the selection of key structure parameters by sensitivity analysis of the prototype design; and(5)the optimization of the prototype design. The approach is demonstrated and validated through a case study of the structure design of a 100 MN hydraulic press.

Design and Optimization of Press Bend Forming Path for Producing Aircraft Integral Panels with Compound Curvatures

In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element method （FEM） equivalent model, the surface curvature analysis, the artificial neural network response surface and the genetic algorithm. The method begins with analyzing the objective＇s shape curvature to determine the bending position. Then it optimizes the punch travel at each bending position by the following steps： （1） Establish a multi-step press bend forming FEM equivalent model, with which the FEM ex- periments designed with the Taguchi method are performed. （2） Construct a back-propagation （BP） neural network response surface with the data from the FEM experiments. （3） Use the genetic algorithm to optimize the neural network response surface as the objective function. Finally, this method is verified by press bending a complicated double-curvature grid-type stiffened panel and bears out its effectiveness and intrinsic worth in designing the press bend forming path.

Forming Path Optimization for Press Bending of Aluminum Alloy Aircraft Integral Panel

Because of the light weight,high stiffness and high structural efficiency,aluminium alloy integral panels are widely used on modern aircrafts.Press bend forming has many advantages,and it becomes a significant technique in aircraft manufacturing field.In order to design the press bend forming path for aircraft integral panels,we propose a novel optimization method which integrates the finite element method(FEM) equivalent model based on our previous study,the artificial neural network response surface,and the genetic algorithm. First,a multi-step press bend forming FEM equivalent model is established,with which the FEM experiments designed with Taguchi method are performed.Then,the backpropagation(BP) neural network response surface is developed with the sample data from the FEM experiments.Further more,genetic algorithm(GA) is applied with the neural network response surface as the objective function.Finally,experimental and simulation verifications are carried out on a single stiffener specimen.The forming error of the panel formed with the optimal path is only 5.37%and the calculating efficiency has been improved by 90.64%.Therefore,this novel optimization method is quite efficient and indispensable for the press bend forming path designing.

Improvement of SiC_p Reinforced Cast AluminiumComposites by the ROC Method

The process of rapid omnidirectional compaction (ROC) of SiCp/cast Al composites was investigated. An apparatus for ROC process was established. Full compactibility of various SiCp/cast Al composites was accomplished. Defects in the materials were eliminated. It is found that after ROC, the tensile strength of the 30% SiCp/Z1109 composite increased by 35%. It is demonstrated that the ROC process is an effective method for improving the performance of SiCp/Al composites.

Innovative manufacturing technology enabling light weighting with steel in commercial vehicles

Improved manufacturing technology is often needed when working with high strength steel. In this re- spect manufacturing technology has to adapt to the altered （and typically reduced） formability and weldability of modern high strength steel. However, this is a rather passive approach from a manufacturing point of view. An indeed much more powerful approach is to generate synergies between innovative manufacturing technology, design and material enabling additional weight savings and efficiency gains. Laser-based material processing, in particular laser welding, offers a wide range of opportunities in this sense. Furthermore, hot stamping and roll forming open up new possibilities for advanced manufacturing of commercial vehicle components. Applications and examples of these technologies will be given in terms of producing innovative semi-products as well as final components.