Industrial application and validation of forming simulation in the flexforming process

Abstract

The flex-forming process is used extensively in aerospace industry for net shape forming of sheet metal structural components. Common metals used in the manufacture of these components include 7075 and 2024 aluminium alloys; usually in an as quenched condition following solution heat treatment. While the process is commonplace, the level of manual rework remains high, driven by inherent process and material variability and the lack of upfront analysis before the manufacture of tooling. A suitable process modelling method using AutoForm is presented along with an industrial validation study for the manufacture of an aerospace frame component in 7075-W aluminium alloy. The results illustrate the importance of material model accuracy and the inclusion of through thickness compressive stresses in predicting the flange springback of the component.