Shaping the future of aircraft parts
Shaping sheet metal is an important manufacturing process for aircraft parts. However, there are disadvantages in traditional methods that use a die, which is a block of metal, to shape panels. These drawbacks include long preparation times and high manufacturing costs. A recent proposal involves replacing the solid dies with two sets of multiple punch matrices that are adjustable in height – multi-point forming. However, there are technological problems to be solved before the full potential of such flexible tooling can be realised. This was the aim of the EU-funded project 'Digitally adjustable tooling for manufacturing of aircraft panels using multi-point forming methodology' (Dataform). It was a specific targeted research project to help strengthen the competiveness of the aerospace industry. A research team of engineers and academics from around Europe and China studied combining multi-point forming technology with robotic-control technology. The project succeeded in the fabrication and testing of three new tooling prototypes: multi-point press forming, stretch forming and positioning. These were integrated within a control unit and computer-aided design, engineering and manufacturing software. The flexible manufacturing system developed can be used to produce three-dimensional (3D) surface panels of different shapes, such as aircraft fuselage and wing cover parts. Complex metal panels of large dimensions and with improved properties can be produced quicker and cheaper with these new forming techniques. It is estimated that tooling costs could be reduced by 60 % and set-up time by up to 50 %.
