Reconfigurable Stretch Forming of Double-Curvature Corrugated Panels
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Solution Overview
Problem
Current manufacturing methods for producing low volume sheet metal components with double curvature and surface textures are costly due to the need for expensive fixed tooling and complex machinery, which limits the production of corrugated and surface textured panels.
Innovation Solution
A reconfigurable metal forming method and apparatus using a flexible interpolator sheet mounted on an array of height-adjustable pins, allowing for the formation of double curvature panels with corrugations or surface features by stretching the workpiece over a reconfigurable forming surface, and enabling the reuse of tooling by changing the interpolator sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed tooling and complex machinery are used to produce double curvature corrugated panels, then manufacturing precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The forming apparatus is segmented into multiple independently adjustable pins that can be individually positioned to create different surface geometries. This modular pin-based system replaces complex fixed tooling while maintaining manufacturing precision through localized control of each pin's position and orientation.
Solution Approach 2:
The apparatus employs dynamically adjustable pins that can be repositioned and reconfigured for different panel designs. This dynamic adaptability eliminates the need for complex fixed tooling changes, allowing the same apparatus to produce various double curvature corrugated panels with different geometries while maintaining dimensional accuracy.
2Manufacturing precision
If fixed tooling is used for producing low volume components, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The pins are designed to be dynamically repositionable and reconfigurable, allowing the apparatus to adapt to different panel designs while maintaining manufacturing precision. Each pin can be adjusted to specific positions and orientations to create various double curvature and corrugation patterns.
Solution Approach 2:
The system changes geometric parameters by adjusting pin positions, heights, and orientations rather than requiring physical tooling changes. This parameter-based control enables precise adaptation to different panel designs while maintaining dimensional accuracy through controlled adjustment of forming surface geometry.
3Strength
If separate reinforcing ribs are attached by riveting or welding, then structural strength is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The forming process merges the creation of the panel body and reinforcing ribs into a single integrated operation. The profiled interpolator sheet simultaneously forms both the panel surface and integrated rib structures, eliminating the need for separate rib attachment equipment and processes while maintaining structural strength.
Solution Approach 2:
The profiled interpolator sheet acts as an intermediary tool that transfers the desired panel geometry including integrated rib structures directly to the workpiece during forming. This intermediary approach creates structurally sound panels with built-in reinforcement without requiring complex assembly equipment for separate rib attachment.
4Shape
If profiled interpolator sheet is used to form corrugations, then surface features are improved, but tooling cost increases
Solution Approach 1:
The interpolator sheet is a flexible thin film component that can be profiled to create various corrugation patterns. This flexible sheet approach is more cost-effective than rigid fixed tooling, as the thin film can be easily manufactured, replaced, or reprofiled to create different surface features without significant tooling investment.
Solution Approach 2:
Surface features are created by changing the geometric parameters of the interpolator sheet profile rather than investing in expensive fixed tooling for each corrugation pattern. The ability to reprofile or replace the interpolator sheet provides cost-effective adaptability for creating different surface features and corrugation geometries.
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 approach reduces tooling costs and increases adaptability, enabling the production of low volume sheet metal components with double curvature and surface textures at a lower cost while maintaining dimensional accuracy, and allows for the creation of integrally stiffened panels by joining smooth and corrugated panels.
Implementation Method 1
stretching the workpiece over the forming surface such that the profiled upper surface of the interpolator sheet forms the desired corrugations or other surface features in the workpiece
Data Source
AI summary
A method of stretch forming a double curvature panel having corrugations or other surface features formed therein includes providing a reconfigurable forming surface defined by a flexible interpolator sheet mounted on an array of height adjustable pins, the interpolator sheet having a profiled upper surface adapted to form corrugations or other surface features in a workpiece as it is stretched over the forming surface, adjusting the height of each pin to suit the shape of the panel to be produced, placing a workpiece onto the forming surface, and stretching the workpiece over the forming surface such that the profiled upper surface of the interpolator sheet forms the desired corrugations or other surface features in the workpiece.