Abstract
Electromagnetic forming (EMF), a technology with advantages of contact-free force and high energy density, generally aims at forming parts by using a fixed coil and one-time discharge. In this study, multi-stage EMF is introduced to form a panel with stiffened grid ribs. The forming rules of the stiffened panel is revealed via analyzing the distribution and evolution of the simulated stress and strain in the ribs and web, where the grid-rib panels were decomposed as the flat panel and two panels with uni-directional ribs (ribs only in X direction or Y direction). It is shown that the forming depth is mainly attributed to the forces on the web, although electromagnetic force is applied on both the ribs and the web, especially, large force on the ribs. The ribs are subjected to uniaxial stress parallel to their directions, and the web is subjected to plane stress in the deformation region. Furthermore, the change of the uniaxial stress characteristic in the X-direction ribs is influenced by the electromagnetic force, reverse bend and inertial effect. The plastic deformation mainly occurs in the Y-direction ribs of the deformation region under a three-direction strain state.
Highlights
Stiffened panels have become important components of modern advanced aircrafts due to their advantages in structure, strength and weight
During the shot peening process, complex experience-based process design and additional prestress treatment [3,4] limit the application of this technology in manufacturing stiffened panels, especially the panels with complicated structure, such as grid-stiffened panels
Study on stress evolution of the grid-stiffened panels is conducted, and the shear stress is neglected since it is obviously smaller than the normal stress from the simulated results
Summary
Stiffened panels have become important components of modern advanced aircrafts due to their advantages in structure, strength and weight. Their study indicated that the EMF shows obvious advantages in eliminating the wrinkling and reducing the springback compared to conventional forming processes, such as hydroforming These unique advantages make the EMF a potential method for forming stiffened panels made of aluminum alloys with excellent electrical conductivity. The complicated structure of aerospace components (such as various curvatures in different directions) makes it difficult to obtain ideal profiles using this method Another idea is the combined forming based on EMF and other forming technologies. The key idea of EMIF is utilizing a small forming coil, moving along some certain designed paths and discharging several times to produce large and complicated parts gradually. The aim of this study is to reveal the forming rules via analyzing the distribution and evolution of the stress and strain through FE simulation, and the influence of the ribs on the stress and strain are discussed with ribs in varied direction arrangements
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