The accuracy of stretch formed sheet metal parts in the aerospace industry depends heavily on tool designer and machine operator expertise. In addition, fixed-configuration facilities and rigid tools result in long lead times, high manufacturing costs and insufficient product quality. In response to this, a methodology combining an adaptive closed-loop shape control algorithm and a reconfigurable forming tool has been developed and implemented for stretch forming. This method is based on empirical estimation of the process characteristics using a 'Deformation Transfer Function' and is capable of rapidly generating a tool shape that produces the desired final part shape, even when significant process uncertainties exist. The same control system is also used to compensate for shape distortions caused by the downstream manufacturing processes of chemical milling and trimming. Experiments involving various compound curvature skins are presented that validate the effectiveness of this methodology in reducing the shape errors below the forming system error threshold in just one or two closed-loop forming trials regardless of skin shape.
Closed-loop shape control of the stretch forming process over a reconfigurable tool: Precision airframe skin fabrication
1999
11 Seiten, 15 Quellen
Conference paper
English
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