Project: Innovative Manufacturing Of Complex Ti Sheet Aeronautical Components

Acronym: 
INMA
Runtime: 
01.09.2010 to 28.02.2014
Status: 
completed project
Programme: 
Framework Programme 7
Approved by
Coordinator
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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.
The INMA consortium is integrated by two end users, one equipment provider, four research organisations, three universities and the EASN association. Participation of industrial partners who will directly exploit the project results guarantees the impact of the project.
IPM-1 has been used to successfully generate a corrected tool path that has been used to fabricate a new geometry that is closer to the desired shape than that produced using an uncorrected tool path. IPM-2 still needs more analysis.
Following rigorous research work, TWI has produced a validated numerical model. Based on a heat input profile supplied by the process engineer, the model is able to simulate the localised heating process of a Ti sheet undergoing asymmetric forming. The model accommodates linear and non-linear heating paths.
Experiments showed that springback error can be predicted with a high level of accuracy. Additionally, results show the optimum values for some of the parameters involved.
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 [...]
1) characterization of mechanical properties and formability of the material TiAL6V4 at various conditions of straining. 2) Description of not only mechanical properties of the processed samples of forming Ti-40, Ti-15-3-3-3, and Ti-6Al-4V alloys sheets, but also homogeneity of their microstructure.
WSK has received a lot of information and data from TECNALIA e.g. roughness values, geometric deviation, tool force, forming steps. WSK cooperated with TECNALIA in intermediate annealing. All TECNALIA experiences will be very useful for making parts using the ISF method in WSK.
An assessment method has been presented to evaluate the energy efficiency of two hot AISF processes. Localised laser heating is a lean alternative compared with global heating. However, an important drawback in localised heating is the excessive residual stress developed due to the combined heating and forming processes. The localised [...]

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Organisations and people involved in this project.

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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