DESCRIPTION

TECHNICAL FIELD

The invention describes the methodology for Forming Deep Contour Sheet metal Parts with Stage plates.

BACKGROUND OF INVENTION

One of the categories of sheet metal parts in Light Combat Aircraft are deep and sharp contours which has to be fabricated using High Pressure Hydraulic Press with single stage tool. The Common problem faced was cracks during forming and thinning of parts. Conventional method of Press forming had problems as below,

a) Wrinkles and overlap of material was observed during press forming, which was very difficult to overcome and resulted in rejection of the parts.

b) Since the part had deep contour involved hand forming which resulted in compromise in quality and time consumption

SUMMARY OF INVENTION

Process of High Pressure Hydraulic Press Forming was optimized by using stage plates and press forming in stages which resulted in quality parts.

PROCESS DETAIL DESCRIPTION

Methodology for forming with stage plates as follows:
a) Press forming the part with stage plates reduces the amount of wrinkles as the stage plate acts as bearing contact surface during pressing in soft condition of raw material.

b) Press forming will be done in stages with the stage plate, as the material is deformed in stages wrinkles and material thinning problems can be eliminated

c) Intermediate dressing will avoid the wrinkle formation

d) Remove extra material with 10 mm extra all round and repress the part after solutionize and trim the final trim the part profile

e) Final part will inspected to confirm the requirements of the drawings.

DRAWINGS

Fig.l: Typical part with complex contour Fig.2: Forming tool with component

CLAIMS

We claim the Methodology followed to form deep contour Sheet Metal parts in Light Combat Aircraft