Reshaping diagrams for bending straightening of forged aeronautical components
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ORIGINAL ARTICLE
Reshaping diagrams for bending straightening of forged aeronautical components ´ Ramiro Mena1,2,3 · Jose´ V. Aguado2 · Stephane Guinard1 · Antonio Huerta3,4 Received: 12 June 2020 / Accepted: 30 July 2020 © Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Large and thick-walled aluminium forgings exhibit shape distortions induced by residual stresses. To restore the nominal geometry, a series of highly manual and time-consuming reshaping operations need to be carried out. In this paper, we are concerned with the development of efficient computer simulation tools to assist operators in bending straightening, which is one of the most common reshaping operations. Our approach is based on the computation of reshaping diagrams, a tool that allows selecting a nearly optimal bending load to be applied in order to minimize distortion. Most importantly, we show that the reshaping diagram needs not to account for the residual stress field, as its only effect is to shift of the reshaping diagram by some offset. That is, the overall behaviour including a realistic 3D residual stress field in a forged part can be retrieved by shifting the residual stress free reshaping diagram by the appropriate offset. Finally, we propose a strategy in order to identify the offset on-the-fly during the reshaping operation using simple force-displacement measures. Keywords Residual stresses · Shape distortion · Bending straightening · Forged parts · Numerical simulation · Reshaping diagrams
1 Introduction Large and thick-walled aluminium forgings are widely used as structural parts in the aeronautical industry. The good Ramiro Mena
[email protected]; [email protected] Jos´e V. Aguado
[email protected] St´ephane Guinard
[email protected] Antonio Huerta
[email protected] 1
Airbus SAS, 18 rue Marius Terce, 31300, Toulouse, France
2
Institut de Calcul Intensif (ICI) at Ecole Centrale de Nantes, 1 rue de la No¨e, 44300, Nantes, France
3
Laboratori de C`alcul Num`eric (LaC`aN). E.T.S. de Ingenieros de Caminos, Canales y Puertos, Universitat Politecnica de Catalunya, Barcelona, Spain
4
Centre Internacional de M`etodes Num`erics a l’Enginyeria (CIMNE), Barcelona, Spain
formability of aluminium, together with its great strengthto-weight ratio, allows producing complex forged parts in an economical way [1]. Additionally, when compared with other metal working processes, such as extensive machining, welding or casting, improved material properties in terms of grain size and orientation are obtained [2]. Aluminium forgings undergo a multiple-step manufacturing process to produce the final aeronautical component. We describe here a typical manufacturing sequence, although others are of course possible. First, forged blanks are typically produced on hydraulic presses with hot closeddies [4]. The process continues with a solution heat treatment (SHT) followed by quenching, which is required to improve the mechanical propertie
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