Numerical and Experimental Investigation of the Innovatory Incremental-Forming Process Dedicated to the Aerospace Indust
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DUE to the increased necessity for environmental protection, new materials, as well as innovative manufacturing solutions, are currently in high demand. As a result of strict European Union regulations, carbon dioxide emissions, noise emissions, and electricity consumption must be reduced during various manufacturing stages. At the same time, customers are demanding reduction in prices (production costs) and improvement in the quality of products. One possible solution to meet these requirements is a reduction in the weight of the commonly used conveyances (i.e., cars, trucks, airplanes, and transport aircrafts). Such a solution makes it possible to reduce, e.g., the amount of consumed fuel and, as a consequence, to reduce the amount of carbon dioxide emission into the atmosphere. A worldwide environmental protection policy insists on limiting factors that are dangerous to the natural environment, which were especially emphasized in the goals of the European Framework Program of Research and Innovation (2014–2020) – ‘‘Horizon 2020.’’ One of the main goals of this program is the production of greener and quieter aircrafts, vehicles, and ships, which will
JOANNA SZYNDLER, Ph.D. Student, and LUKASZ MADEJ, Professor, are with the AGH University of Science and Technology, Al. Mickiewicza 30, 30-059 Krako´w, Poland. Contact e-mail: [email protected] FRANCISZEK GROSMAN, Professor, and MAREK TKOCZ, Assistant Professor, are with the Silesian University of Technology, Akademicka 2A, 44-100 Gliwice, Poland. Manuscript submitted March 3, 2015. METALLURGICAL AND MATERIALS TRANSACTIONS A
contribute to the improvement of environmental protection by noticeable reduction in noise and vibrations. As a result, more and more research has been dealing with these issues. However, this research has been mostly concentrated on reduction in emission of harmful substances produced by an air transport. Such research has been clearly visible in 7th Framework Program projects, such as NINHA, X-NOISE EV, MARS, or DAEDALOS. One of the suggested solutions is the successive decrease in aircraft weight by using lightweight composites. However, not every component of the aircraft body can be made from these light materials. This is obvious in the case of structural parts, which are crucial from a safety point of view and have to be characterized by high durability and load-carrying capacity. In these applications, metallic materials are still widely used to manufacture subsequent components, which are then assembled and joined together in the final product used in the aircraft construction. Thus, to reduce the weight of these assembled components, a so-called integral part made from lightweight alloys, e.g., aluminum, titanium, or magnesium, can be introduced. An integral element is made from one piece of material, which is equivalent to the product in a conventional approach that is made from many smaller parts.[1] Avoidance of joints (welds, rivets), which weaken the whole component, causes the product to become lighter, more durable, an
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