Electromagnetic Field Shaper for Consistent Joggle Bend Forming
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Solution Overview
Problem
Current methods for forming joggle bends in metal stringers for aircraft manufacturing are time-consuming and prone to issues like spring back and die geometry problems, often requiring higher temperatures and resulting in inconsistent product quality.
Innovation Solution
A part forming system utilizing an electromagnetic field shaping system, where a field shaper with a cavity receives a workpiece and die, and an electromagnetic field from a main coil applies magnetic pressure to bend the workpiece into a desired shape, allowing for higher velocity and lower temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional press and die methods are used to form joggle bends, then the workpiece can be shaped to follow the surface of the mating structure, but the process is time-consuming and requires higher temperatures
Solution Approach 1:
The patent replaces the traditional mechanical press and die system with an electromagnetic field-based forming system. The electromagnetic field generates magnetic pressure to deform the workpiece, eliminating the need for mechanical presses while achieving the same shaping objective. This substitution enables faster processing speeds and improved consistency in forming joggle bends.
Solution Approach 2:
The patent changes the fundamental parameter of the forming process from mechanical force to electromagnetic field intensity. By controlling the electromagnetic field parameters (current, frequency, duration), the system can precisely control the magnetic pressure applied to the workpiece, enabling rapid and consistent deformation without the limitations of mechanical press capacity and speed.
2Ease of manufacture
If higher temperatures are used in the forming process, then the material becomes more formable, but spring back and die geometry problems occur reducing quality consistency
Solution Approach 1:
The patent changes the temperature parameter from elevated to ambient or reduced levels. The electromagnetic field generates sufficient magnetic pressure to deform the material at lower temperatures, eliminating the need for thermal softening. This parameter change prevents the spring back and die geometry issues that occur with high-temperature processing, resulting in more consistent joggle bend quality.
Solution Approach 2:
The electromagnetic forming system replaces mechanical pressing with magnetic pressure, which distributes force more uniformly across the workpiece. This substitution eliminates the localized high-stress concentrations that cause die geometry problems and spring back, achieving consistent forming at lower temperatures.
3Manufacturing precision
If multiple presses are used to form complex shapes, then the desired geometry can be achieved, but the device complexity and processing time increase
Solution Approach 1:
The electromagnetic field forming system serves as a universal forming apparatus that can create various complex geometries without requiring multiple specialized presses. By adjusting the electromagnetic field parameters and the configuration of the field shaper and die, the same system can form different shapes and features, eliminating the need for multiple presses and reducing device complexity.
Solution Approach 2:
The electromagnetic field system replaces multiple mechanical presses with a single electromagnetic forming apparatus. The magnetic pressure can be precisely controlled and distributed to achieve complex geometries in a single operation, whereas traditional mechanical systems would require sequential pressing operations with multiple presses, increasing both complexity and processing time.
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 reduces spring back and improves consistency and reproducibility of joggle bends, enabling faster production without the need for elevated temperatures or additional presses, resulting in higher quality parts.
Implementation Method 1
an electromagnetic field from the main coil is applied to the field shaper
Implementation Method 2
The electromagnetic field causes a magnetic pressure that bends the workpiece on a die into a desired shape
Data Source
AI summary
A method, system, and apparatus for a part forming system. The part forming system comprises a field shaper having a cavity configured to receive a workpiece and a die. The field shaper has a number of dimensions based on being inserted into a main coil. The workpiece is bent to form a part with a desired shape when an electromagnetic field from the main coil is applied to the field shaper while the field shaper is located within the main coil.