Curved Workpiece Forming Sequence to Limit Strain and Furnace Size
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Solution Overview
Problem
Existing methods for forming curved workpieces, such as aircraft components, risk material breakage due to plastic strain accumulation and require large treatment furnaces for solution heat treatment.
Innovation Solution
A method involving a first forming step to impart a cross-sectional shape, followed by solution heat treatment, and a second forming step to bend the workpiece into an arcuate shape, with optional third forming to match a curved surface, using a device with supporting parts and rollers to manage strain and reduce furnace size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the carving roll step is performed on the plate material which is in a state where the plastic strain has been introduced, then the desired contour can be provided, but the plate material may be broken starting from the plastic strain or the plastic strain may increase cumulatively
Solution Approach 1:
The invention performs the carving roll step (providing desired contour) before the solution heat treatment step, rather than after. By completing the contour forming operation while the material is still in its original state without accumulated plastic strain from cross-sectional forming, the risk of material breakage during or after heat treatment is significantly reduced. The sequence is deliberately reversed from conventional approaches to prevent breakage issues.
Solution Approach 2:
The invention changes the sequence parameter of processing steps, specifically performing contour forming before heat treatment rather than after. This parameter change in process sequencing allows the material to be in a more favorable mechanical state during contour forming, avoiding the accumulation of plastic strain that would occur if cross-sectional forming were performed first on hardened material.
2Strength
If the workpiece formed to have a curved shape is subjected to the solution heat treatment, then the workpiece can be hardened, but the volume of the treatment furnace required may be increased
Solution Approach 1:
The invention performs the solution heat treatment step before the contour roll step that creates the curved shape. By completing the heat treatment operation while the workpiece is still in a straight, uncurved state, the volume required for the treatment furnace is significantly reduced. The curved shaping operation is deliberately delayed until after heat treatment, allowing the use of a more compact furnace.
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
Enhances workpiece strength, reduces breakage risk, and minimizes treatment furnace size while ensuring accurate bending and handling of high-hardness workpieces.
Implementation Method 1
a solution heat treatment step of performing solution heat treatment on the workpiece after the first forming step has been performed
Data Source
AI summary
A workpiece processing method includes: a section roll forming step of subjecting a flat plate shaped workpiece to forming to impart a prescribed cross-sectional shape thereto; a solution heat treatment step of subjecting the workpiece, after the section roll forming step has been performed, to solution heat treatment; a contour roll forming step of subjecting the workpiece, after the solution heat treatment step has been performed, to forming to bend the workpiece into an arcuate shape; and a stretch forming step of subjecting the workpiece, after the contour roll forming step has been performed, to forming to impart a curved shape, following a curved surface of a die, to the workpiece by bringing the workpiece into contact with the curved surface and inputting a tension load to the workpiece.