Submitted by: Eric Blasiman, Business Development Manager – SMF Sales
Introduction: In this blog, we will explore how Quintus Technologies has revolutionized the sheet metal forming process for aircraft doorframes. By implementing high-pressure forming technology, innovative tool design, and AutoForm’s simulation software, Quintus has successfully reduced the number of production steps from sixteen to just three, resulting in significant cost savings and increased productivity.
Background: The aerospace industry traditionally used pressing techniques with only one die to minimize tool costs. Quintus Technologies takes this concept further by operating at a much higher pressure of up to 1,400 bar (20,000 psi) compared to the usual 200-300 bar (3,000-4,350 psi) offered by other suppliers. The higher pressure, combined with innovative tool design, allows for the production of complex shapes in fewer steps, eliminating the need for intermediate hand corrections and heat treatments. By utilizing AutoForm forming software, we can predict wrinkling, part thinning, and springback, as well as develop product processes and blank geometry before any tool production and tryout has started.
Figure 1: Quintus Flexform Fluid Cell press
Aircraft Doorframe: The focus of this optimization process is a doorframe for large commercial aircraft. The doorframe is manufactured using 2 mm (0.08″) aluminum 2024-T42 and features a complex shape with a large central indentation, six non-circular holes, and an undercut.
Figure 2: Position of the component
Figure 3: Dimensions of the component
Initial Feasibility Evaluation: The original manufacturing process for the doorframe involved sixteen steps, including the preparation of the blank. By introducing a new tool design and raising the pressure from 300 bar (4,350 psi) to 800 bar (11,600 psi), Quintus was able to reduce the number of pressing operations to two, resulting in a total of six manufacturing steps. This optimization led to significant part production cost savings, estimated to be around 0.5 million euros per year, and increased production capacity.
Figure 4: The support walls of the forming tool (beige in the image)
Further Process Optimization: Quintus’s application team recently tested if it would be possible to further optimize the production process for the doorframe. Through accurate simulations and extensive experience in designing dies, Quintus engineers were able to reduce the number of pressing operations to just one. This final optimization reduced the total manufacturing process to only three steps, including the preparation of the blank.
Figure 5: AutoForm visualization of the part and FLD
Tool Design: The new die designed by Quintus takes full advantage of the high pressure offered by their presses. The support walls on the die help direct the pressure, enabling accurate forming of the sides and the undercut.
Figure 6: The pre-cut blank resting on the forming tool
Figure 7: The final part after forming
Figure 8: The final part after pressing
Results: To evaluate the accuracy and repeatability of the process, five samples were pressed and 3D scanned. The collected data showed excellent repeatability, further confirming the effectiveness of the optimized process.
Figure 9: Cross sections used for the evaluation
Conclusion: By implementing modern tool design, AutoForm forming software, and high-pressure forming technology, Quintus Technologies has successfully optimized the sheet metal forming process for aircraft doorframes. The reduction in production steps from sixteen to just three has resulted in significant cost savings and increased productivity. Accurate simulations and innovative tool design have played a crucial role in achieving these improvements. Quintus Technologies offers full support, from advice to complete tool designs, to help manufacturers optimize their manufacturing processes and achieve high-quality, cost-effective production.
For more information, please visit: White Paper | Optimizing Sheet Metal Forming – Aircraft Doorframe | Quintus Technologies.
To talk with our team directly: Contact | Quintus Technologies
Submitted by: Eric Blasiman, Business Development Manager – SMF Sales
Quintus Technologies, LLC
Email: Eric.Blasiman@QuintusTeam.com