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Electromagnetic flanging: from elementary geometries to aeronautical components

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Abstract

Aeronautical companies are manufacturing many components of small (less than 200 mm) and medium (between 200 mm and 1000 mm) sizes by flexforming. In order to diversify the production facilities of these components, these companies are interested in evaluating the ability of electromagnetic forming processes to produce small parts. This paper describes the design of a set of experiments of electromagnetic flanging with some elementary geometries, whose purpose is to enlighten several geometrical defect issues encountered, and to propose some solutions. A particular attention is first paid to the straight flange, which allows to analyse, understand and then correct the main defect issues that can occur during the forming. The proposed solutions consist of some particular design of the inductors and the dies, in order to adjust the profile of the loading and the kinematics of bending of the flange to obtain the desired final geometry. Next, curved flanges are addressed, and finally the forming of a model aeronautical part combining several elementary geometries of flange is described. Promising results are obtained. In these experiments, sheets of 1, 2 and 1.6 mm thickness made of aluminium alloy 2024-T4 and sheets of 0.5 mm thickness made of aluminium alloy 1050 are used. The geometric dispersions and the material soundness of the parts have been controlled. Besides, a numerical model of the model aeronautical part has been developed in the LS-DYNA computing environment, whose final purpose is to facilitate the design of the coil. The results of the numerical simulations are shown to be qualitatively in accordance with experimental results.

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Acknowledgements

This study is part of the HPP project managed by IRT Jules Vernes (French Institute in Research and Technology in advanced manufacturing Technologies for composite, metallic and hybrid structures). The authors wish to acknowledge the industrial and academic partners of the project: Airbus, Airbus Group Innovations, Constellium, Europe Technologies, Stelia Aerospace and Ecole Centrale de Nantes respectively. The authors also wish to acknowledge DynaS+ for the simulation performed on LS-DYNA.

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Authors and Affiliations

  1. IRT Jules Verne, Chemin du Chaffault, 44340, Bouguenais, France

    Cheikh Tidiane Sow

  2. STELIA Aerospace, 13 Boulevard des Apprentis, 44600, Saint-Nazaire, France

    Grégoire Bazin

  3. Research Institute in Civil and Mechanical Engineering (GeM, UMR 6183 CNRS), École Centrale de Nantes, 1 rue de la Noë, F-44321, Nantes, France

    Thomas Heuzé & Guillaume Racineux

Authors
  1. Cheikh Tidiane Sow
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  2. Grégoire Bazin
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  3. Thomas Heuzé
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  4. Guillaume Racineux
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Correspondence to Thomas Heuzé.

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Sow, C.T., Bazin, G., Heuzé, T. et al. Electromagnetic flanging: from elementary geometries to aeronautical components. Int J Mater Form 13, 423–443 (2020). https://doi.org/10.1007/s12289-020-01547-y

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  • DOI: https://doi.org/10.1007/s12289-020-01547-y

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