Arena project PTC October 2015 - Hydroforming Design Light AB

Purpose and goal

The project aimed to demonstrate the hydro forming manufacturing method for a strut to rear engine stands for an aircraft engine. In the work simulation and practical experiments have been used to show that it is possible to form parts with tight inner radii avoiding wrinkles, cracks or thinning in the material in question. Evaluation of the manufactured validation geometry shows that the tolerance requirements are not achieved all over the part geometry. Methods, tools and data to improve performance in this regard is the project outcome and is available for future applications.

Expected results and effects

Material data and simulations have been developed. Tools was manufactured and adapted and validation geometries have been evaluated. The real pressure profile of the liquid has been studied and modified to be included in the simulation. Buckling at closing of the tools has been verified through simulation and friction effects have been studied. Overall, the effects of this are that simulation can be used to develop the tool design and process so that good form filling can be achieved. Thus, one can expect to be able to tackle more advanced geometric challenges with simulation.

Planned approach and implementation

The work was planned to be done in steps. Basic conditions such as choice of geometry and materials were made early. Thereafter, material data for simulation was produced. In step 1, a simpler validation geometry was used. Verification was done via simulation, physical tests and measurements. Comparisons between tool geometry, physical article, model and simulation results have been done. The plan for step 2 was to use experience from step 1 to tackle a more complex geometry to give confidence in the feasible geometry. However, the resource requirements in step 1 did not allow for step 2.