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Fracture prediction in the forming of aircraft Al stiffeners using multi-point dies

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Abstract

Press bending is widely used in Al integral panels for the aerospace industry, which, combined with multi-point dies, is an innovative approach. In the forming process, the fracture on integral panels is a fatal flaw. In this study, it mainly presents a core method on how to predict fracture on stiffeners by a novel method—the multi-point press bending. With the combination of a multi-point press bending experiment and corresponding finite element method (FEM) simulation, a suitable ductile criterion was selected to predict fracture on an aircraft Al stiffener. Using the fracture criterion, the fracture moments and fracture positions on stiffeners were determined in the multi-point press bending process. Due to the rapid reconfigurable characteristic of multi-point die, an optimal deformation path was discussed to reduce the fracture risk on stiffeners. It was identified that the Cockcroft criterion proved to be the most favorable ductile fracture criterion to predict fracture on stiffeners. Moreover, in the multi-point press bending process of the 7B04-T7451 Al stiffener, it is not prone to fracture with the increase of forming steps. Multi-point forming with an equidifferent curvature deformation path reduces the fracture risk of stiffeners much more than that with an equidifferent radius deformation path.

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Authors and Affiliations

  1. Roll Forging Research Institute, Jilin University (Nanling Campus), No. 5988 Renmin Street, Changchun, 130025, People’s Republic of China

    Chun-guo Liu, Jing Li, Ya-nan Dong, Xue-guang Zhang & Tao Yue

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  1. Chun-guo Liu
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  2. Jing Li
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  3. Ya-nan Dong
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  4. Xue-guang Zhang
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  5. Tao Yue
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Correspondence to Chun-guo Liu.

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Liu, Cg., Li, J., Dong, Yn. et al. Fracture prediction in the forming of aircraft Al stiffeners using multi-point dies. Int J Adv Manuf Technol 90, 3109–3118 (2017). https://doi.org/10.1007/s00170-016-9634-9

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