Elastic-Plastic Reduced Order Modelling of Sheet and Profiles Bending-under-Tension

The aircrafts fuselage structure is usually composed of an assembly of stringers and frames made of cold-worked aluminium profiles. In particular, frames need of a forming process that shapes the profile into the frame’s curved shape. To do this, both profile ends are clamped, and then the profile is simultaneously stretched and pressed against the mould so that the material is plastically deformed. Industrial experience shows that most of times the resultant frame does not fulfil neither curvature nor planarity tolerances. These defects are mainly due to spring-back, residual stresses, and some technologic restrictions related to the machinery. The lack of understanding has led industry to reduce the automation level, and thus the forming process is frequently interrupted to perform verifications and adjustments that make the process to be time-consuming and very much dependent on the know-how of the machine operator. Aiming to improve the frame’s industrialisation, this work first analyses the influence of several parameters in the final shape. Then, we propose a computer-aided forming process based on the concept of Computational Vademecum (CV), which is also introduced in this work. It allows reducing the dependence on the operator know-how, while reliability and repeatability of the process can be improved.

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