Innovation: Hot Incremental Forming Process Using Localized Heating

Last update: 19.06.2014
Approved by
Coordinator
Is this your eco-innovation?
Update here.
Demo
Case studies in: 
Keywords: 
hot incremental forming, local heating, resistance heating, laser heating, titanium
The INMA project aims at developing an intelligent knowledge-based (KB) flexible manufacturing technology for titanium shaping that will lead to drastically reduce current aircraft development costs incurred by the fabrication of complex titanium sheet components with a minimal environmental impact. In particular, this project aims at strengthening European aircraft industry competitiveness, by transforming the current non-flexible and cost intensive forming processes into a rapid and agile manufacturing process.

This brand new technology, based on Asymmetric incremental sheet forming (AISF), will transform the way many titanium sheet aeronautical components such as after pylon fairings, fan blades, exhaust ducts or air collectors are manufactured today. The innovative, cost-efficient and ecological forming technology to shape complex geometries in titanium that will contribute to strengthen the European aircraft industry competitiveness meeting society's needs.

Currently, aircraft industry uses complicated and cost intensive forming processes to shape complex Ti sheet components, such as deep drawing, hot forming, super plastic forming (SPF) and hydroforming. In some cases parts are even obtained by hand working. These techniques show severe drawbacks which include high costs, long industrialisation phases and high energy consumption rates.
On the contrary, main features of the innovative AISF technology to be developed will be an increased flexibility, cost reduction, minimised energy consumption and a speed up in the industrialisation phase.

The major impacts of the results obtained in the INMA project will be:
- Cost incurred by dedicated tooling will be reduced by 80%
- The component lead times will decrease by 90%
- Buy-to-fly ratios will be up to 20% lower

The INMA Consortium is integrated by 2 end-users, 1 equipment provider, 4 research organisations, 3 universities and the EASN association. Participation of industrial partners who will directly exploit the project results will guarantee the impact of the project.

PROJECT GOALS:

The goals of the project are the following:

- Development of the AISF process for titanium through the generation of experimental data about adequate parameter windows, tool specifications and tool paths for cold, hot and large scale forming.
- Implement and validate numerical AISF process models that will provide reliable prediction of the forces, strains and shape deviations resulting from cold, lean heated and large scale forming.
- Characterize titanium formability limits, including the definition of specific and inexistent testing and evaluating procedures, as well as its post-forming metallurgical, mechanical and chemical properties under cold and hot AISF.
- Implement and validate an intelligent KB AISF process model that will serve to correct the forming tool path in order to compensate shape deviations appearing when no die is used.
- Develop heating procedures that will allow tackling hot AISF operations at minimum cost and energy consumption without compromising other relevant issues such as efficiency and reliability.
- Apply and validate the developed technology through the fabrication of aircraft and aeroengine realistic pilot demonstrators.
Two local heating methods for hot incremental sheet forming (ISF) have been developed in order to extend the application of ISF to materials with a low formability at room temperature, like e.g. TiAl6V4. Localized heating aims at the reduction of energy consumption in hot forming processes.
Two experimental setups for hot incremental forming processes using localized heating have been successfully developed. One setup is based on localized resistance heating whereas the second setup is based on local laser heating. For both processes the general applicability has been demonstrated. In order to ensure safe and stable processes and to adjust the desired forming temperature, an automated temperature control has been developed for both processes. In resistance heating surface quality is a problematic issue, whereas the local laser heating shows very promising results. It has been shown that the developed hot incremental forming processes using localized heating are able to decrease the forming forces and to increase the formability with increasing temperature. Experiments on the max. formable wall angle have been conducted with TiAl6V4 sheet material.

We are sorry. There is currently no information available in this section.

This innovation is the result of the project

Title: Innovative Manufacturing Of Complex Ti Sheet Aeronautical Components

Acronym: 
INMA

Runtime: 
01.09.2010 to 28.02.2014

Status: 
completed project

Organisations and people involved in this eco-innovation.

Please click on an entry to view all contact details.

FUNDACION TECNALIA RESEARCH & INNOVATION

Field: Scientific research and development (Spain)

Role in project: Project Coordination

Contact person: Ms. PENALVA Mariluz

Website: http://www.tecnalia.com

Phone: +34-943 105 115

Contact

AIRBUS OPERATIONS SAS

(France)

Contact person: Mr. PICOT Thierry

Phone: +33-561936172

Contact

EADS DEUTSCHLAND GMBH

(Germany)

Contact person: Mr. LANG Werner

Website: http://www.eads.net

Phone: +49-8960728653

Contact

EASN TECHNOLOGY INNOVATION SERVICES BVBA

(Belgium)

Contact person: Dr. PAPADOPOULOS Michael

Phone: +30-2610911547

Contact

INDUSTRIAS PUIGJANER S.A.

(Spain)

Contact person: Mr. MASAGUÉ Daniel

Website: http://www.denn.es

Phone: +34-937132001

Contact

RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHEN

(Germany)

Contact person: Prof. SCHMACHTENBERG Ernst

Website: http://www.rwth-aachen.de

Phone: +49-2418090490

Contact

THE UNIVERSITY OF LIVERPOOL

(United Kingdom)

Contact person: Ms. SHAW Veronica

Website: http://www.liverpool.ac.uk

Phone: +44-1517948722

Contact

TWI LIMITED

(United Kingdom)

Contact person: Ms. PARKER Lucy

Website: http://www.twi.co.uk

Phone: +44-01223899532

Contact

UNIVERSITY OF PATRAS

(Greece)

Contact person: Prof. LAMPEAS George

Website: http://www.upatras.gr

Phone: +30-2610969498

Contact

VYZKUMNY A ZKUSEBNI LETECKY USTAV A.S.

(Czech Republic)

Contact person: Ms. MAKOVSKA Pavlina

Website: http://www.vzlu.cz

Phone: +420-225115367

Contact

WYTWORNIA SPRZETU KOMUNIKACYJNEGO PZL - RZESZOW SA

(Poland)

Contact person: Mr. HALIGOWSKI Robert

Website: http://www.wskrz.com

Phone: +48-178667388

Contact