Wrinkling Analysis and Process Optimization of the Hydroforming Processes of Uncured Fiber Metal Laminates for Aircraft Fairing Structures.
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| Title: | Wrinkling Analysis and Process Optimization of the Hydroforming Processes of Uncured Fiber Metal Laminates for Aircraft Fairing Structures. |
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| Authors: | Chen, Yunlong1 (AUTHOR), Liu, Shichen1 (AUTHOR) liusc94@xmu.edu.cn |
| Source: | Polymers (20734360). Aug2025, Vol. 17 Issue 16, p2267. 16p. |
| Subjects: | Wrinkle patterns, Process optimization, Aerospace industries, Laminated materials, Aerospace industry equipment, Airframes, Finite element method |
| Abstract: | Lightweight composite structures like fiber metal laminates (FMLs) are widely used to manufacture aircraft structures and substitute metallic parts. While the superior mechanical performance of FMLs, including their high specific strength and excellent impact and fatigue resistance, has gained the interest of many researchers in the aerospace manufacturing industry, there are still some challenges that need to be considered. Conventional approaches like lay-up techniques and autoclave molding can achieve the relatively simple FML parts with large radii and profiles required for aircraft fuselages and flat skins. However, these methods are not suitable for forming complex-shaped structural parts due to the limited failure strain of fiber-reinforced materials and complex failure modes of the laminates. This research puts forward a new methodology that combines the hydroforming and subsequent curing process to investigate the feasibility of manufacturing complex aircraft parts like fairings made by FMLs. In this research, wrinkle formations are analyzed under various parameters during the hydroforming process. The geometrical shape of the initial blanks and the parameters, including blank holder force and cavity pressure, have been optimized to avoid flange edge wrinkles, and the addition of local support materials contributes to improving local wrinkling in the sharp corners. A finite element model (FEM) taking material laws, interlayer contacts, and boundary conditions into account is used to predict the dynamic hydroforming process of the fiber metal laminate, and experimental works are carried out for its verification. It is expected that the proposed method will reduce both costs and time, as well as reducing laminate defects. Thus, this method offers great potential for future applications related to manufacturing complex-shaped aerospace parts. [ABSTRACT FROM AUTHOR] |
| Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Header | DbId: egs DbLabel: Engineering Source An: 187612766 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Wrinkling Analysis and Process Optimization of the Hydroforming Processes of Uncured Fiber Metal Laminates for Aircraft Fairing Structures. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Chen%2C+Yunlong%22">Chen, Yunlong</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Shichen%22">Liu, Shichen</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> liusc94@xmu.edu.cn</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Polymers+%2820734360%29%22">Polymers (20734360)</searchLink>. Aug2025, Vol. 17 Issue 16, p2267. 16p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Wrinkle+patterns%22">Wrinkle patterns</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Aerospace+industries%22">Aerospace industries</searchLink><br /><searchLink fieldCode="DE" term="%22Laminated+materials%22">Laminated materials</searchLink><br /><searchLink fieldCode="DE" term="%22Aerospace+industry+equipment%22">Aerospace industry equipment</searchLink><br /><searchLink fieldCode="DE" term="%22Airframes%22">Airframes</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Lightweight composite structures like fiber metal laminates (FMLs) are widely used to manufacture aircraft structures and substitute metallic parts. While the superior mechanical performance of FMLs, including their high specific strength and excellent impact and fatigue resistance, has gained the interest of many researchers in the aerospace manufacturing industry, there are still some challenges that need to be considered. Conventional approaches like lay-up techniques and autoclave molding can achieve the relatively simple FML parts with large radii and profiles required for aircraft fuselages and flat skins. However, these methods are not suitable for forming complex-shaped structural parts due to the limited failure strain of fiber-reinforced materials and complex failure modes of the laminates. This research puts forward a new methodology that combines the hydroforming and subsequent curing process to investigate the feasibility of manufacturing complex aircraft parts like fairings made by FMLs. In this research, wrinkle formations are analyzed under various parameters during the hydroforming process. The geometrical shape of the initial blanks and the parameters, including blank holder force and cavity pressure, have been optimized to avoid flange edge wrinkles, and the addition of local support materials contributes to improving local wrinkling in the sharp corners. A finite element model (FEM) taking material laws, interlayer contacts, and boundary conditions into account is used to predict the dynamic hydroforming process of the fiber metal laminate, and experimental works are carried out for its verification. It is expected that the proposed method will reduce both costs and time, as well as reducing laminate defects. Thus, this method offers great potential for future applications related to manufacturing complex-shaped aerospace parts. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/polym17162267 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 16 StartPage: 2267 Subjects: – SubjectFull: Wrinkle patterns Type: general – SubjectFull: Process optimization Type: general – SubjectFull: Aerospace industries Type: general – SubjectFull: Laminated materials Type: general – SubjectFull: Aerospace industry equipment Type: general – SubjectFull: Airframes Type: general – SubjectFull: Finite element method Type: general Titles: – TitleFull: Wrinkling Analysis and Process Optimization of the Hydroforming Processes of Uncured Fiber Metal Laminates for Aircraft Fairing Structures. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Chen, Yunlong – PersonEntity: Name: NameFull: Liu, Shichen IsPartOfRelationships: – BibEntity: Dates: – D: 15 M: 08 Text: Aug2025 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 20734360 Numbering: – Type: volume Value: 17 – Type: issue Value: 16 Titles: – TitleFull: Polymers (20734360) Type: main |
| ResultId | 1 |
