Monolithic Branching Component Rollforming With Controlled Thickness
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Solution Overview
Problem
Rollforming processes in aircraft manufacturing result in reduced thickness of profile segments, leading to increased production costs and operational complexities due to the need for additional heat treatment and manual reshaping, while compromising structural integrity.
Innovation Solution
A method involving rollforming and split-rollforming of sheet metal to create monolithic components with integral branching points, ensuring seamless integration and uniform thickness through controlled thinning and flange formation, utilizing symmetry and parallel planes for enhanced structural integrity and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rollforming is used to manufacture profile components, then production cost is reduced, but profile thickness is reduced in split segments
Solution Approach 1:
The profile is divided into multiple segments through split-rollforming, with the second section being split into separate segments while the first section remains intact. This segmentation allows different portions of the profile to have different thickness characteristics, resolving the contradiction by maintaining full thickness in critical areas while enabling cost-effective rollforming in other areas.
Solution Approach 2:
Different sections of the profile are given different qualities - the first section maintains original thickness for structural integrity, while the second section is split and thinned for cost-effective manufacturing. This local differentiation allows the component to satisfy both cost reduction requirements and thickness requirements in different locations.
2Manufacturing precision
If pressforming is used to manufacture frame components, then profile thickness is maintained, but additional heat treatment and manual reshaping steps are required
Solution Approach 1:
The invention combines rollforming and split-rollforming processes into a single integrated manufacturing flow, eliminating the need for separate heat treatment and manual reshaping steps required by traditional pressforming. This merging of processes maintains profile thickness while reducing overall process complexity.
Solution Approach 2:
The rollforming process operates continuously to produce the profile with integrated branching points, avoiding the discontinuous nature of pressforming followed by heat treatment and manual reshaping. This continuous process maintains thickness while simplifying the manufacturing workflow.
3Ease of manufacture
If split-rollforming is used to create branching points, then manufacturing cost is reduced, but profile thickness is reduced in split segments
Solution Approach 1:
The profile is strategically segmented at the branching points through split-rollforming, concentrating the thickness reduction only at non-critical locations where branches are formed, while maintaining full thickness in the main structural sections. This selective segmentation resolves the contradiction between cost reduction and strength maintenance.
Solution Approach 2:
Different local regions of the profile have different thickness characteristics - critical load-bearing sections maintain original thickness for strength, while branch regions undergo thinning for cost-effective manufacturing. This local quality differentiation allows simultaneous achievement of cost reduction and strength requirements.
Data Source
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AI summary
The invention relates to a method (100) for manufacturing a monolithic component with integral branching points, comprising the following steps: (S1) providing a sheet metal (10) comprising a first section (12) and a second section (14), (S2) thinning, via rollforming, the first section (12) of the sheet metal (10), (S3) splitting, via split-rollforming, the second section (14) of the sheet metal (10) in a plane parallel to a surface area of the second section (14), such that a first flange portion (16) and a second flange portion (18) is formed.