Potential applications of peen forming finite element modelling

Abstract

► A finite element methodology was applied for peen forming of aerospace components. ► The method combines dynamic and static simulations to lower computational cost. ► The response of complex parts to sequential forming treatments was predicted. ► This reduces the dependence of process development upon costly experimental testing. ► This approach has great potential at different stages of the component lifecycle. Peen forming is a versatile and flexible manufacturing process commonly used in the aerospace industry to shape wing skins and rockets panels. Development of peening parameters needed to obtain a specific component shape can be both costly and challenging due to the use of empirical methods which involve large quantities of physical experiments coupled with trial and error processing of prototype components. Many iterations are often required to get the desired shape with no guarantee that a specific component geometry can be achieved. Reliable numerical simulations could substantially reduce the time, cost and risk associated with process development. The purpose of this study is to further investigate the use of numerical tools to model the peen forming process. This work combines static and dynamic simulation techniques to predict the development of curvature on representative wing skin panels that include features such as integral stiffeners. This work illustrates the considerable potential of finite element simulations to determine the process parameters needed to produce a component design, and substantially reduce the dependence upon physical testing.