Gourd Petal Forming With Segmented Pulse Heating Uniformity

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Solution Overview

Problem

Existing methods for forming gourd petal components in launch vehicle fuel tanks result in components with low quality due to uneven current and Joule heat distribution during electric pulse creep aging, leading to inconsistent deformation and forming issues.

Innovation Solution

A method involving a sheet material with a stepped shape, divided into rectangular blocks, where first and second wires are evenly distributed to ensure uniform current density and temperature distribution, using electric pulses to heat and form the gourd petal component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electric pulse heating is applied to the sheet material during creep aging forming, then the forming speed and efficiency are improved, but the current and Joule heat distribution becomes uneven, leading to inconsistent deformation and reduced forming quality

Engineering Contradiction:

Improveforming speedVSAvoidforming quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The sheet material is divided into multiple rectangular blocks, with each block independently heated by electric pulses. This segmentation allows for controlled and uniform heat distribution across different regions, preventing the uneven heating that previously caused inconsistent deformation while maintaining high forming speed.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the sheet material is heated to creep aging temperature for a longer time to improve forming quality, then the deformation consistency is improved, but the energy consumption and production time increase

Engineering Contradiction:

Improvedeformation consistencyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Electric pulses are applied periodically to heat the sheet material to creep aging temperature. This periodic heating method allows the material to reach the required temperature quickly and maintain it for the necessary duration, achieving consistent deformation without excessive production time or energy consumption.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The temperature and time parameters are optimized by applying electric pulses that rapidly heat the sheet material to the creep aging temperature range. This parameter control ensures consistent deformation while minimizing the total time required, as the material is heated efficiently and held at the optimal temperature for the precise duration needed.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If conventional heating methods are used to avoid complex current distribution issues, then the equipment complexity is reduced, but the forming efficiency and productivity decrease

Engineering Contradiction:

Improveequipment complexityVSAvoidforming efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

Conventional mechanical or thermal heating systems are replaced with an electric pulse heating system. Although this increases electrical system complexity, it dramatically improves forming efficiency by rapidly heating the sheet material to creep aging temperature, enabling faster production cycles that outweigh the additional equipment complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Achieves uniform temperature distribution and improved forming quality of gourd petal components with high efficiency by controlling current density and Joule heat distribution, resulting in consistent deformation and enhanced component quality.

Implementation Method 1

applying electric pulses to M areas including different installation ends respectively, so that a current flows from one end of the sheet material to be formed to the other end of the sheet material to be formed to heat each area of the M areas of the sheet material to be formed respectively

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

maintaining a temperature generated by a load and an electric pulse for a preset time length to allow the sheet material to be formed to undergo a creep aging forming

Methodology Applied

Scientific EffectCreep: Creep

Data Source

PatentUS12460287B2Method for forming gourd petal component using electric pulse creep aging

Publication Date: 2025.11.04 CENT SOUTH UNIV

AI summary

A method for forming a gourd petal component is provided. The method includes obtaining a sheet material with M installation ends. Second wires are divided into M groups based on a cross-sectional area of each installation end. The sheet material is installed on a flexible mold. First wires and the second wires are connected to the sheet material and a current cabinet respectively. A power supply is turned on, electric pulses are applied to M areas including different installation ends for heating. When a temperature of the sheet material reaches a creep aging temperature, a load is applied on a top of the flexible mold to adsorb the sheet material. A creep aging forming is maintained for a preset time under the load and a high temperature. Once the load and the external current are unloaded, the gourd petal component is obtained after a cooling.