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deep roll forming

A deep-rolling, compression-force technology for manufacturing tooling, shipping and packaging, fuselage bulkheads, etc., which can solve time-consuming masking/de-masking steps, increased workpiece surface roughness, expensive lasers, etc.

Active Publication Date: 2020-06-26
THE BOEING CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, laser shock hardening requires expensive equipment and time-consuming masking / demasking steps before and after forming
[0004] These methods also increase the surface roughness of the workpiece, thereby requiring additional time-consuming and costly surface preparation after the curved surface has been introduced into the sheet metal

Method used

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Embodiment approach

[0044] Clause 1. A method of forming a surface structure from a workpiece, the method comprising:

[0045] providing a workpiece comprising a first side and a second side, the workpiece having a thickness of about 2 inches or less;

[0046] positioning the workpiece on the positioner such that the first side of the workpiece is accessible to the deep rolling tool;

[0047] applying a compressive force to the first side of the workpiece using a deep rolling tool;

[0048] moving the deep rolling tool relative to the workpiece while continuously applying a compressive force to introduce plastic deformation to the first portion of the workpiece;

[0049] adjusting the deep rolling tool to contact the second portion of the workpiece and moving the deep rolling tool relative to the workpiece to introduce plastic deformation to the second portion of the workpiece; and

[0050] The deep rolling tool is adjusted to introduce plastic deformation to the one or more additional portions...

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Abstract

The name of the invention is deep roll forming. Methods and systems for forming curved structures using deep rolling are disclosed. The method includes introducing plastic deformation to one or more portions of a workpiece using deep rolling to form a convex curved surface in the workpiece. The workpiece and the subsequently formed surface structure can be metallic or composite. For example, the disclosed deep rolling systems and methods form curved aircraft panels while also providing improved fatigue strength and low levels of work hardening during the forming process rather than post-production surface treatments.

Description

technical field [0001] The present teachings relate generally to forming contoured structures, and more specifically to forming contoured structures using deep rolling. Background technique [0002] Modern aircraft utilize curved structures, such as curved sheet metal, in a variety of applications including skins, viewing panels, wing flaps, and fuselage sections. Conventional methods of forming curved sheet metal include shot peening and laser shockpeening. In shot peening forming, a stream of metal, glass or ceramic shot impacts the surface of a metal workpiece to elastically and plastically stretch the surface and introduce local low plastic deformations, which manifest themselves as residual compressive stresses. The combination of elastic and plastic tensile and compressive stresses creates a concave curvature of the metal sheet on the shot peened side. Problems arise with shot peening due to process variability. Also, shot peening uses small shot peening, usually ma...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): B23P9/02
CPCB23P9/02C21D7/08B24B39/00B21D3/14B21D3/02B21D53/92B21D31/005B21B1/08B64C1/12
Inventor H·张R·P·库阿尔伯格
Owner THE BOEING CO