On the Development of Lofts for Doubly Curved Sheet Metal Components

Practical automated flat pattern generation with inbuilt production features for doubly curved sheet metal components (SMCs) is addressed here utilizing a new and unique Point Transformation Algorithm (PTA). This is the third in the series of papers on practical Flat Pattern Development (FPD) [8] and Production Loft Generation Systems (PLGS) [9] complementing the pioneering work [6,7]. In the first two publications, automated loft generation programs have addressed sheet metal components having a Principal Flat Surface (PFS) only. The flat pattern development of 3-D components that do not have the flat surface(termed as Non-PFS components) having complex features of double curvature in addition to cutouts and nibbled holes typical of aircraft components were so far not addressed due to lack of relevant published algorithms. This paper traces the evolution of developments and provides the record of fully illustrated, automated loft generation scheme for aircraft SMCs including the Non-PFS components which underwent validation through production tests by sponsors. Details of some of the unique features of the system like simplified surface model generation, termed as topological model and powerful algorithms deployed with potential for CAD/CAM applications are included.