Annular Part Forming for Extended Trailing Edge Aerodynamics
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Solution Overview
Problem
Current methods for forming annular parts, such as aircraft nacelle lip skins, are complex and costly due to the need for multi-stage processes and unsuitable deep drawing processes for extended trailing edges, which hinder efficient production and aerodynamic performance.
Innovation Solution
A method involving the formation of a conical or frusto-conical preform using a punch, clamping, and gripping means to achieve coaxial movement, allowing for a single-stage process with adjustable axial forces and taper angles to minimize springback and optimize the extended outer trailing edge, enabling the production of annular parts with improved aerodynamic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deep drawing processes are used to manufacture extended trailing edges, then the aerodynamic performance is improved, but the process suitability and manufacturing capability deteriorate
Solution Approach 1:
The invention changes the fundamental forming parameters from deep drawing to a combination of stretching and drawing operations. The process uses a punch with specific geometric parameters (radius, profile) and controlled movement parameters (velocity, position) to achieve extended trailing edges that cannot be produced by conventional deep drawing, thereby resolving the contradiction between aerodynamic performance and manufacturability
2Manufacturing precision
If multi-stage forming processes are used for complex three dimensional shapes, then the manufacturing precision is improved, but the device complexity and production cost increase
Solution Approach 1:
The invention merges multiple forming operations (stretching, drawing, and shaping) into a single integrated process. The punch design combines multiple functional elements (forming surface, gripping features, positioning elements) that would traditionally require separate tools and stages, thereby achieving complex three-dimensional shapes with reduced device complexity while maintaining manufacturing precision
3Adaptability or versatility
If intermediate heat treatments are applied during forming, then the material formability is improved, but the production time and process complexity increase
Solution Approach 1:
The invention applies preliminary action by pre-heating the material or pre-forming a near-net-shape configuration that requires minimal subsequent forming. This allows the material to achieve the required complex geometry through a single continuous process without intermediate heat treatments, thereby improving material formability while reducing production time and process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the efficient and cost-effective production of annular parts with extended trailing edges, enhancing laminar flow and reducing drag by minimizing flow interruptions, thus addressing the limitations of existing processes.
Implementation Method 1
applying an axial force between the aft clamp assembly member and forward clamp assembly member
Implementation Method 2
clamping a large diameter end of the preform in the clamping means and gripping a second small diameter end of the preform in the gripping means
Implementation Method 3
causing relative co-axial movement between the gripping means and the punch so that the portion of the wall of the preform between the punch and the gripping means is formed over the leading edge of the punch
Data Source
AI summary
A method of forming an annular part includes forming a conical or frusto-conical preform with at least one open end, initiating an actuation means to cause relative coaxial movement only between a punch, a clamping means and a gripping means, thereby clamping a large diameter end of the preform in the clamping means and gripping a second small diameter end of the preform in the gripping means and the external surface of the punch to engage the internal surface of the preform, and causing relative co-axial movement between the gripping means and the punch so that the portion of the wall of the preform between the punch and the gripping means is formed over the leading edge of the punch.