Skip to main content
SpringerLink
Log in

Investigation on three-roller cylindrical bending of 2060-T8 Al-Li alloy plate for aircraft fuselage skin components

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

The aluminum-lithium alloy 2060-T8 is widely utilized in the fabrication of future aircrafts. With the application of this high-strength alloy, the severe shape variation after unloading has been challenging the traditional process for forming fuselage skin components. In this study, the three-roller bending process with the 2060-T8 alloy for fuselage skins was investigated with theoretical calculations, finite simulations and experiments. Uniaxial tensile tests of 2060-T8 alloy were carried out and three-roller cylindrical bending experiments were accomplished. The prediction with analytic models was conducted to determine the upper roller feeding and residual stress with the desired radius. To promote the predicting accuracy, an adaptive fitting method was adopted to determine the elastic-exponential hardening model variably. The same forming processes were also simulated with Abaqus software for comparison. Finally, the configuration and residual stress of the experimental plates were measured. The forming curves predicted with different approaches were presented in the comparison with measurements. The good agreement of the theoretical estimations verified the analytic models with variable material model. The crucial reason caused the decrease of predicting accuracy in theoretical calculation was revealed in the analysis and verifications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. Rioja RJ, Liu J (2012) The evolution of Al-Li base products for aerospace and apace applications. Metall Mater Trans A 43(9):3325–3337. doi:10.1007/s11661-012-1155-z

    Article  Google Scholar 

  2. Prasad NE, Gokhale A, Wanhill RJH (2013) Aluminum-lithium alloys: processing, properties, and applications. Butterworth-heinemann, Oxford

  3. Bodily B, Heinimann M, Bray G, Colvin E, Witters J (2012) Advanced aluminum and aluminum-lithium solutions for derivative and next generation aerospace structures. SAE technical paper 2012–01–1874. doi:10.4271/2012-01-1874

  4. Dursun T, Soutis C (2014) Recent developments in advanced aircraft aluminium alloys. Mater Des 56:862–871. doi:10.1016/j.matdes.2013.12.002

    Article  Google Scholar 

  5. Li J, Wang S (2016) Distortion caused by residual stresses in machining aeronautical aluminum alloy parts: recent advances. Int J Adv Manuf Technol 1–16. doi:10.1007/s00170-016-9066-6

  6. Leacock AG, McCracken D, Brown D, McMurray R (2012) Numerical simulation of the four roll bending process. Mater Manuf Process 27(4):370–376. doi:10.1080/10426914.2011.560228

    Article  Google Scholar 

  7. Tvergaard V, Needleman A (1975) On the buckling of elastic-plastic columns with asymmetric cross-sections. Int J Mech Sci 17(6):419–424. doi:10.1016/0020-7403(75)90039-9

    Article  Google Scholar 

  8. Hansen N, Jannerup O (1979) Modelling of elastic-plastic bending of beams using a roller bending machine. J Manuf Sci Eng 101(3):304–310

    Google Scholar 

  9. Hardt D, Constantine E, Wright A (1992) A model of the sequential bending process for manufacturing simulation. J Manuf Sci Eng 114(2):181–187

    Article  Google Scholar 

  10. Xu F (1991) Calculation of the exerting force necessary to form the aircraft hull plate in the symmetry plate bender with three rolls and the feeding value of the centre roll. Acta Aeronautica Et Astronautica Sinica 12(7):A401–A410

    Google Scholar 

  11. Mao YS, Hou L, Wang CF (2003) Calculation and auto-control model of plate roll-bending forming. Shipbuilding of China 44(161):74–80

    Google Scholar 

  12. Gandhi A, Raval H (2008) Analytical and empirical modeling of top roller position for three-roller cylindrical bending of plates and its experimental verification. J Mater Process Technol 197(1):268–278

    Article  Google Scholar 

  13. Tran QH, Champliaud H, Feng Z, Dao TM (2014) Analysis of the asymmetrical roll bending process through dynamic FE simulations and experimental study. Int J Adv Manuf Technol 75(5):1233–1244. doi:10.1007/s00170-014-6176-x

    Article  Google Scholar 

  14. Tran HQ (2014) Asymmetrical roll bending process study: dynamic finite element modeling and experiments. Université du Québec: École de technologie supérieure, Québec

    Google Scholar 

  15. Chudasama MK, Raval HK (2013) An approximate bending force prediction for 3-roller conical bending process. Int J Mater Form 6(2):303–314. doi:10.1007/s12289-011-1087-y

    Article  Google Scholar 

  16. Shim D, Son J, Lee E, Baek G (2016) Improvement strategy for edge waviness in roll bending process of corrugated sheet metals. Int J Mater Form 1–16. doi:10.1007/s12289-016-1303-x

  17. Cai Z, Li M, Lan Y (2012) Three-dimensional sheet metal continuous forming process based on flexible roll bending: principle and experiments. J Mater Process Technol 212(1):120–127. doi:10.1016/j.jmatprotec.2011.08.014

    Article  Google Scholar 

  18. Coleman TF, Li Y (1994) On the convergence of reflective newton methods for large-scale nonlinear minimization subject to bounds. Math Program 67(2):189–224

    Article  MATH  Google Scholar 

  19. Coleman TF, Li Y (1996) An interior, trust region approach for nonlinear minimization subject to bounds. SIAM J Optim 6:418–445

    Article  MathSciNet  MATH  Google Scholar 

  20. Cai Z, Diao K, Wu X, Wan M (2016) Constitutive modeling of evolving plasticity in high strength steel sheets. Int J Mech Sci 107:43–57. doi:10.1016/j.ijmecsci.2016.01.006

    Article  Google Scholar 

  21. Barlat F, Brem JC, Yoon JW, Chung K, Dick RE, Lege DJ, Pourboghrat F, Choi SH, Chu E (2003) Plane stress yield function for aluminum alloy sheets—part 1: theory. Int J Plast 19(9):1297–1319. doi:10.1016/S0749-6419(02)00019-0

    Article  MATH  Google Scholar 

  22. Ktari A, Antar Z, Haddar N, Elleuch K (2012) Modeling and computation of the three-roller bending process of steel sheets. J Mech Sci Technol 26(1):123–128. doi:10.1007/s12206-011-0936-4

    Article  Google Scholar 

  23. Schuster S, Gibmeier J (2016) Incremental hole drilling for residual stress analysis of strongly textured material states – a new calibration approach. Exp Mech 56(3):369–380. doi:10.1007/s11340-015-0104-3

    Article  Google Scholar 

  24. Li J, Wang H, Sun G, Chen B, Chen Y, Pang B, Zhang Y, Wang Y, Zhang C, Gong J, Liu Y (2015) Neutron diffractometer RSND for residual stress analysis at CAEP. Nuclear Instruments and Methods in Physics Research Section A: Accelerators, Spectrometers, Detectors and Associated Equipment 783:76–79. doi:10.1016/j.nima.2015.02.026

    Article  Google Scholar 

Download references

Acknowledgements

The HONGDU Aviation Industry (Group) Corporation Limited provided the material and the roller-bending machine for this study. The authors would like to acknowledge the funding support to this research from the program of “Technology Research on Roller Bending of Al-Li Alloy for Skins on Commercial Aircraft C919”.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China

    Jingwen Peng, Weidong Li & Min Wan

  2. Key Laboratory for Neutron Physics of Chinese Academy of Engineering Physics, Institute of Nuclear Physics and Chemistry, Mianyang, 621999, China

    Changsheng Zhang, Jian Li & Guangai Sun

Authors
  1. Jingwen Peng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Weidong Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Min Wan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Changsheng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jian Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Guangai Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Weidong Li.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Peng, J., Li, W., Wan, M. et al. Investigation on three-roller cylindrical bending of 2060-T8 Al-Li alloy plate for aircraft fuselage skin components. Int J Mater Form 11, 269–278 (2018). https://doi.org/10.1007/s12289-017-1350-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-017-1350-y

Keywords

Search

Navigation