Superplastic Forming Friction Layer for Wrinkle Mitigation
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Solution Overview
Problem
Conventional methods for mitigating wrinkles in super-plastically formed parts are inefficient and costly, as incorporating hard features into the die geometry is difficult and often requires multiple adjustments to achieve optimal wrinkle mitigation.
Innovation Solution
A method involving the application of a friction-modifying layer with non-uniform thicknesses to specific portions of the part assembly, combined with controlled stress management through flanges and surface irregularities, to uniformly distribute stress and reduce wrinkles during super-plastic formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard features are incorporated into the die geometry to mitigate wrinkles, then wrinkle mitigation is improved, but device complexity and manufacturing difficulty increase substantially
Solution Approach 1:
The patent applies friction-modifying layers with different coefficients of friction to specific local regions of the die surface corresponding to wrinkle-prone areas. Instead of modifying the entire die geometry, only specific locations receive friction-modifying treatment, thereby reducing overall device complexity while maintaining wrinkle mitigation effectiveness.
Solution Approach 2:
The patent changes the friction parameter at specific die locations by applying friction-modifying layers or coatings. This parameter change allows for wrinkle control without altering the fundamental die geometry, thus avoiding increased device complexity while achieving the desired wrinkle mitigation.
2Reliability
If hard features are incorporated into the die geometry to mitigate wrinkles, then wrinkle mitigation is improved, but manufacturing cost and time increase due to multiple adjustments
Solution Approach 1:
The patent applies friction-modifying layers to the die surface before the super-plastic forming process. This preliminary action allows for wrinkle mitigation to be built into the process setup, eliminating the need for multiple trial-and-error adjustments during production and thereby improving ease of manufacture.
Solution Approach 2:
The patent uses friction-modifying layers or coatings that can be applied relatively cheaply and renewed if necessary, rather than permanently modifying the expensive die geometry. This approach reduces manufacturing costs and simplifies the modification process.
3Ease of manufacture
If the coefficient of friction is uniformly distributed across the die surface, then manufacturing simplicity is maintained, but wrinkle mitigation effectiveness decreases
Solution Approach 1:
The patent deliberately creates non-uniform friction distribution by applying friction-modifying layers to specific regions of the die surface. This local differentiation of friction properties targets wrinkle-prone areas with higher friction while maintaining lower friction in other regions, thereby improving wrinkle mitigation effectiveness without significantly complicating the manufacturing process.
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 wrinkle-mitigated or wrinkle-free super-plastically formed parts by ensuring a consistent stress state across the manufacturing process, reducing the need for costly die modifications and trial-and-error adjustments.
Implementation Method 1
applying a friction-modifying layer to the first outer sheet of the part assembly... The friction-modifying layer is applied at a first thickness in the first portion and a second thickness in the second portion
Implementation Method 2
super-plastically form the part assembly into the formed part... moving an upper die of the die system in a forming direction toward the lower die to stretch and compress the part assembly
Data Source
AI summary
A method including arranging a plurality of flat sheets into a part assembly, consisting of a first outer sheet and a second outer sheet. A friction-modifying layer is applied to the first outer sheet, where the first outer sheet has a first portion and a second portion. The friction-modifying layer is applied at a first thickness in the first portion and a second thickness in the second portion. The first thickness and the second thickness are different thicknesses. The method also includes placing the part assembly on a lower die of a die system with the first outer sheet facing the lower die. The method further includes moving an upper die of the die system in a forming direction toward the lower die to stretch and compress the part assembly between the upper die and the lower die and to super-plastically form the part assembly into the formed part.