Modeling and evaluation of defects occurrence reasons while isothermal punching of ribbed panels from aluminum alloys

Аuthors

Galkin V. I.^1*, Paltievich A. R.^1**, Shelest A. E.^2***

1. Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia
2. Baikova Institute of Metallurgy and Materials Science Russian Academy of Sciences, 49, Leninsky prospect, Moscow, 119334, Russia

*e-mail: galkin@mati.ru
**e-mail: a-paltievich@yandex.ru
***e-mail: shelest99@mail.ru

Abstract

Ribbed panels from aluminum alloys are widely used in aircraft industry as power structural elements, parts of the wing and fuel tanks, as well as in the form of the heat-exchange surfaces. Increased requirements on strength and reliability are rendered to such panels. The most rational technique for such kind of panel manufacturing, i. e. isothermal punching, may lead to clipping in the ribs and sink marks on the side, opposite to the ribbing.

Modeling and experimental results of the studies reveal that defects stems from the combination of manufacturing process control parameters, such as temperature and deformation velocity, as well as geometrics, i. e. blank thickness.

The main objective of the studies consists in developing design technique of the part blank design as a function of temperature and deformation velocity while isothermal punching.

The put forward problem is solved by control polynom development, linking manufacturing process parameters – the blank temperature, velocity and geometrics with the defect magnitude, i. e. sink marks in the ribbed aluminum panel while its manufacturing by isothermal punching technique.

The initial data for the required polynomial is the results of finite element mathematical modeling with varying initial parameters of the punching process and the magnitude of the forming sink mark or its absence.

The obtained modeling results were processed according to the three-way analysis of variance planning procedure. The regression equation was obtained to compute the sink mark magnitude in the ribbed panel in dependence of the process temperature and velocity, as well as the initial blank thickness.

The authors applied the analysis of variance, which allowed define the significant factors in the calculated polynomial, and, neglecting the rest, significantly simplify it.

The sink mark magnitude obtained with the calculated polynomial correlated well with the results of mathematical modeling and experimental studies.

The proposed method is universal and can be implemented for various cases of defect-free technological processes design, when evaluating the impact of the process's control parameters on and their contribution to the manufactured product's characteristic being studied is required.

Keywords:

isothermal stamping, ribbed panels, mathematical planning of the experiment, three-way analysis of variance, functional dependencies, sink mark

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