Efficient shaping or reshaping of complex 3D parts using engineered residual stress

ABSTRACT:Increasing emphasis on affordability of military systems has led to a number of advances in airframe production. For example, high speed machining (HSM) has made it possible to fabricate thin structures that provide improved performance. However, near-surface plastic strains induced by HSM or surface treatments can lead to excessive component distortion such that the component requires reshaping, resulting in additional cost. In other cases, surface treatments are applied specifically to reach a target distorted shape. In Phase I a novel approach for developing a reliable analytical procedure was investigated and a successful validation experiment indicated that the Phase I prototype reshaping software tool represented a significant step forward toward the final goal of the project: to optimize machining and surface treatment processes for complex components such that a target deformation can be achieved with quantified uncertainty. The Phase II effort will focus on further development of the prototype software tool in order to demonstrate its use in an operational environment. ESRD will collaborate with The Boeing Company to refine requirements and demonstrate the predictive performance of this software tool on a typical aerospace component. This system should lead to substantial cost savings in the manufacturing of metallic aerospace components.BENEFIT:The vehicle for commercialization of the new technological capabilities will be ESRD's software product StressCheck which is already being used by major aerospace OEMs, primarily for special applications and detailed analysis at the subcomponent and component levels. It provides the infrastructure necessary for supporting hierarchic modeling and solution verification procedures. The key to successful commercialization is the development of metrics that demonstrate not only the new technological capabilities but also the substantial economic benefits in terms of cost reductions derived from enabling designers to model design alternatives without having to perform extensive testing of prototypes. The economic benefit is known: Boeing has expressed that it expects substantial savings to be realized in manufacturing of unitized structures with this new technology.The primary market for the technical capabilities to be developed is both military and commercial aircraft manufacturers. This includes the major OEMs and their suppliers. In the Phase I project The Boeing Company provided ESRD with a Letter of Support for developing the technology and Boeing is continuing its involvement as a subcontractor for Phase II, and as such, the initial commercialization will be within Boeing. As complex unitized components are becoming more common in the aerospace industry the need becomes greater for a virtual distortion modeling system, and there should be extensive need within other aerospace OEMs as well for a software tool that enhances reliability and reduces the cost of complex components. Substantial market opportunities also exist in automotive, shipbuilding, and other industries that perform surface treatments on metallic components.