Abstract
The countersinking process is affected by many factors including the tools and the workpiece parameters. Some forming phenomena such as the knife-edge affect the quality of the countersunk hole. Up to now, many kinds of research rely mainly on experiments which lead to poor quality and difficult control of this process. In this paper, a proposed numerical optimization of the countersinking process is developed to obtain a normalized countersunk hole. This optimization approach is based on the response surface method (RSM), design of experiments (DOE) and sequential quadratic programming (SQP). The finite element model is performed with an elasto-plastic behaviour for simulating the process. A configuration with an imposed displacement applied to the blank holder is adopted in this study. The comparison between the results of the numerical model and the experiments showed a good agreement.
Highlights
In the industries, such as the aircraft manufactories, the countersunk hole is widely used to joint plates with rivets or screws.The countersinking process using forming techniques improves productivity and decreases the cost and gives good mechanical properties with no waste of material
Park et al [1] studied the effect of the fastener load transfers on the cracking behaviour in the countersunk holes of the joint specimens
It is proposed to use the cold expansion for the countersunk hole to enhance the fatigue life [2]
Summary
In the industries, such as the aircraft manufactories, the countersunk hole is widely used to joint plates with rivets or screws.The countersinking process using forming techniques improves productivity and decreases the cost and gives good mechanical properties with no waste of material. In the industries, such as the aircraft manufactories, the countersunk hole is widely used to joint plates with rivets or screws. The quality of the countersunk hole plays an interesting role to ensure the rigidity and the accuracy of the joined plates. Many recent pieces of research have been focused on crack behaviour and fatigue life. Park et al [1] studied the effect of the fastener load transfers on the cracking behaviour in the countersunk holes of the joint specimens. It is proposed to use the cold expansion for the countersunk hole to enhance the fatigue life [2]. Some other works are interested in studying the stress concentration factors in a countersunk hole in plates [3]
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