Economical laser-based shaping of aluminium parts One of the main targets of aircraft manufacturers is increased integration to decrease weight and reduce manufacturing costs. Laser beam forming (LBF) has the potential to produce huge economic benefits because it is easily automated and eliminates the need for costly forming tools currently being used. Industrial Technologies © Achim Schoberth To date, LBF has not been investigated for use in the aircraft industry, although its application in the telecommunications industry, in computer peripherals such as CD drives and DVDs, and in automotive lamps among others is widespread. The EU-funded ‘Economic advanced shaping processes for integral structures’ (Ecoshape) project set out to develop LBF processes to reduce the assembly cost of fuselage and wing structures. The LBF process injects heat within a sheet enabling it to be formed. However, the temperature distribution within the sheet varies with thickness and the resulting temperature gradient causes different stresses to develop in different areas. Thus, the researchers first focused on optimising laser parameters for minimal material degradation combined with maximum formable sheet thickness for all selected materials. They then developed the laser forming process for single curvature (two-dimensional (2D)) geometries and enhanced the process to handle more complex stiffened biaxial (3D) curved shapes. The investigators developed an online simulation and measurement tool for the LBF process and integrated it with a control system for forming aluminium structures. The algorithms included self-learning correction functions as well as robotic-based LBF application. Finally, the researchers conducted a financial analysis to enhance exploitation of results. In summary, the Ecoshape project successfully applied LBF methods for the first time to aircraft components. The researchers combined simulation, control and online 3D shape measurement to produce a tool capable of fast, reliable and robust laser forming of aluminium-based structures, promising economic benefits for the European aircraft industry as well as economic growth for the EU.
