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Advanced tooling designs can accomplish more than producing
good parts. They are frequently a key component in
a broader analysis of the entire manufacturing process for a
given part. These assessments are particularly beneficial for
complex formed parts that require a high number of discreet
production operations. The fundamental goal is to
enable the Flexform press and a redesigned tool to remove
as many of these operations as possible, especially the hand
forming bottlenecks often required to correct wrinkling,
deformation and springback.
The example on this page is typical of the time and cost
savings possible with process analysis. The part (Figure 11)
is made from aluminium alloy, and is nearly two metres in
length, with numerous manufacturing challenges: significant
hoop strain conditions due to its large circumference, joggles
in a number of planes, undercuts, and deep flanges.
The original manufacturing process included a total of 17
separate operations,
and yielded an average
of 240 finished
parts per month.
A thorough assessment
was conducted
to identify those tasks
that could be eliminated by
redesigning the forming tool. The
new tool (Figure 12) was instrumental
in reducing the number of
processing steps from 17 to six. As
shown in Figure 13, the steps
eliminated included four Flexform
press cycles plus the associated tool loading/unloading time, 2.5 hours in
hand forming time and five other out-of-press operations.
The new streamlined manufacturing process quadrupled the yield, producing
240 parts in a week rather than a month. Component recurring costs have
been cut by 50%. The new process also permitted a productive reallocation
of skilled labour hours and better utilisation of equipment.
-5-
Current
Manufacturing
Process
1st Flexform Pressing
2nd Flexform
Band Saw
Hand Rout
1st Hand Adjustment
3rd Flexform Pressing
De-grease
Anneal
2nd Hand Adjustment
4th Flexform Pressing
5th Flexform Pressing
Solution Treatment
3rd Hand Adjustment
5th Flexform Pressing
4th Hand Adjustment
5-Axis Rout
5th Hand Adjustment
Improved
Manufacturing
Process
1st Flexform Pressing
Solution Treatment
2nd Flexform
Pressing
1st Hand Adjustment
5-Axis Rout
2nd Hand Adjustment
Figure 13. Detailed process analysis and new
tooling result in dramatic time and cost savings
for this complex component for a major airliner.
Process assessment and restructuring
Figure 11
Figure 12
For decades, fluid cell pressing has been an established
but sub-optimized production process for suppliers to the
aerospace industry. The dramatic advances in tooling
and process design discussed above now make
Flexforming an even more cost effective technique for an
expanding variety of complex formed metal components.
Avure Technologies is the world’s largest producer of
Flexform presses. Agon Consultancy has accelerated the
tooling research work done by Avure over the past 40
years, focusing not only on tool design but also on
streamlining the forming process. Both companies share
a common interest in making Flexforming an economically
viable technology at all levels of the supply chain.
-6-
Conclusion
Sales in the Americas:
Avure Technologies, Inc.
Columbus, Ohio USA
Phone: +1 614-891-2732
New knowledge of the behaviour of aerospace alloys
under high pressure results in new tooling concepts
and new opportunities for suppliers to take full
advantage of the cost and quality benefits of
Flexforming.
This new precision, easily incorporated into Catia V5 CAD platforms, provides
critical support to the aerospace industry’s “part-to-part” manufacturing philosophy.
Until now, component assembly time has often been excessive due to misalignment
caused by failure of the component to meet key assembly tolerance
specifications. In addition, parts are generally made with pilot holes, requiring redrilling
prior to attachment. Now, Flexforming can produce components that fit
the first time, with full-size holes, speeding assembly operations significantly by
eliminating time wasted on manual rework, multiple positioning and re-positioning,
and redundant drilling.
These closer tolerance parts can also promote greater use of friction stir welding,
a joining process that is two to three times faster than traditional riveting, with a
subsequent reduction in the weight of the airframe.
Quality parts speed aircraft assembly
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