Titanium Vacuum Forming With Sacrificial Core and Bladed Fixture
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Solution Overview
Problem
Current methods for forming large titanium parts are costly due to expensive die tooling and require thick titanium plates, multiple machining operations, and stress relief procedures, leading to high manufacturing costs and potential distortion.
Innovation Solution
A method involving vacuum forming that uses thin titanium plates, bending, roll-forming, and a bladed form fixture with thermal vacuum stress relief to produce large titanium parts efficiently, reducing tooling costs and machining-induced stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional heated press and matched die tooling are used to form large titanium parts, then the parts can be formed with acceptable quality, but the tooling cost becomes very expensive and thick titanium plates are required
Solution Approach 1:
The patent replaces expensive matched die tooling with a disposable sacrificial core made of inexpensive material (such as foam or plastic). The core is inserted into a simple vacuum bag mold, allowing the titanium plate to be formed around it. After forming, the core is removed and discarded. This approach eliminates the need for costly precision tooling while maintaining part quality.
Solution Approach 2:
The patent introduces a vacuum bag as an intermediary forming mechanism between the titanium plate and the final part shape. The vacuum bag, when sealed around the sacrificial core and subjected to vacuum pressure, transfers the core's shape to the titanium plate without requiring complex tooling. This intermediary system enables cost-effective formation of large parts.
2Productivity
If traditional methods are used to form large titanium parts, then the parts can be produced, but multiple machining operations and stress relief procedures are required, adding time and cost
Solution Approach 1:
The patent performs stress relief heating as a preliminary action before machining operations. By heating the formed titanium part to relieve residual stresses from the forming process, the part stabilizes its dimensions and reduces distortion during subsequent machining. This preliminary stress relief eliminates the need for multiple stress relief procedures after machining, saving time.
Solution Approach 2:
The patent replaces multiple mechanical machining operations with a more efficient process sequence. The vacuum forming process itself creates near-net-shape parts with minimal material removal required, substituting for extensive conventional machining. Combined with preliminary stress relief, this reduces the total number of machining operations and overall manufacturing time.
3Manufacturing precision
If thick titanium plates are used to form large parts, then the parts can be formed without distortion, but the material cost increases and the final part thickness cannot be reduced
Solution Approach 1:
The patent changes the forming parameters by using vacuum pressure (negative pressure) instead of conventional positive pressure forming. This vacuum forming process, combined with the sacrificial core method, allows thin titanium plates to be formed without distortion because the vacuum pressure evenly distributes the forming forces. This parameter change enables the use of thinner, more cost-effective titanium material while maintaining dimensional stability.
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
Enables the cost-effective formation of large titanium parts from thin plates with reduced machining operations and stress relief procedures, minimizing distortion and tooling expenses while maintaining part quality.
Implementation Method 1
The fixture part is placed in a thermal vacuum furnace and a stress-relieving operation is performed
Data Source
AI summary
A method for forming large titanium parts includes forming bends into a titanium plate for form a bent part. The bent part is then roll-formed to form contours into the bent part. The surfaces of the contoured part are rough-machined, and the part is then secured to a bladed form fixture. The bladed form fixture comprises a plurality of header boards that secure the part to the fixture. The fixture part is placed in a thermal vacuum furnace and a stress-relieving operation is performed. The part is removed from the fixture and final machining takes place.