Segmented Die Assembly for Near-Net Aircraft Part Forming
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Solution Overview
Problem
Conventional methods for forming large and complex aircraft parts are inefficient, leading to increased costs, complexity, and production time due to the need for large blanks, high raw material usage, and extensive milling processes.
Innovation Solution
A segmented die assembly comprising upper and lower die sections with releasably coupled segments, allowing for longitudinal stability and transverse movement, heated to high temperatures using integrated heating elements, and coupled with a movable gantry press and robotic system for efficient deformation of thinner blanks into finished parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processes are used to form large aircraft parts, then the parts can be produced, but production time, cost, and complexity increase significantly
Solution Approach 1:
The die is divided into multiple segments that can be assembled in different configurations. Each segment can be independently positioned and secured, allowing the die to be customized for different part geometries while maintaining a manageable, modular structure that reduces overall system complexity.
Solution Approach 2:
The die segments are designed with movable and adjustable components, including segments that can be positioned in different locations and orientations. This dynamic configuration capability allows the same die system to adapt to various part designs, reducing the need for multiple specialized dies and lowering process complexity.
2Quantity of substance
If thick metal blanks are used for creep forming, then large parts can be formed, but material costs and waste increase
Solution Approach 1:
The die system enables forming of parts from thinner metal blanks by utilizing controlled creep deformation at elevated temperatures. By adjusting temperature, pressure, and time parameters during the forming process, the material can be strategically deformed to achieve the desired part geometry from a more material-efficient blank, reducing both raw material costs and waste.
3Manufacturing precision
If extensive milling processes are used to finish parts, then precise dimensions can be achieved, but milling time and costs increase
Solution Approach 1:
The creep forming process is designed to pre-shape the metal blank into a configuration that closely approximates the final part geometry. By performing the bulk of the shaping work during the forming stage rather than through subsequent milling operations, the part achieves near-net-shape dimensions that require minimal finishing, thereby reducing milling time while maintaining precision.
4Ease of operation
If segmented die design is implemented, then die assembly and disassembly is easier, but coupling structure complexity increases
Solution Approach 1:
The coupling mechanism uses removable fasteners and detachable connection elements that can be easily inserted and removed. This extraction approach allows die segments to be quickly assembled and disassembled without requiring complex permanent joints, maintaining ease of operation while managing coupling structure complexity through standardized, simple connection features.
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 enables the formation of large parts with complex profiles using smaller blanks, reducing material waste, milling time, and costs, while increasing productivity and reducing worker stress and tool consumption.
Implementation Method 1
a plurality of heating elements coupled to at least one of the upper segmented die or the lower segmented die, wherein the plurality of heating elements are configured to heat the at least one of the upper segmented die or the lower segmented die to at least a predetermined temperature
Data Source
AI summary
A die assembly for forming finished parts from blanks includes an upper die section and a lower die section. The upper die section includes an upper segmented die having a plurality of upper die segments releasably coupled to each other. The lower die section includes a lower segmented die having a plurality of lower die segments releasably coupled to each other. The die assembly is usable with a movable gantry press configured to move to a location of the die assembly and operate the die assembly.