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MSC.SOFTWARE WORLDWIDE AEROSPACE CONFERENCE and TECHNOLOGY SHOWCASE TOULOUSE, April 8-10, 2002

MSC.SOFTWARE WORLDWIDE AEROSPACE CONFERENCE and TECHNOLOGY SHOWCASE TOULOUSE, April 8-10, 2002 Numerical simulation of the Super Plastic Forming Process of the EFA – 2000 Under Carriage Door F. Giordano  – A. Natale  – M. Calcagni .  Alenia Aerospazio – Divisione Aeronautica

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MSC.SOFTWARE WORLDWIDE AEROSPACE CONFERENCE and TECHNOLOGY SHOWCASE TOULOUSE, April 8-10, 2002

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  1. MSC.SOFTWARE WORLDWIDE AEROSPACE CONFERENCE and TECHNOLOGY SHOWCASE TOULOUSE, April 8-10, 2002 Numerical simulation of the Super Plastic Forming Process of the EFA – 2000 Under Carriage Door F. Giordano– A. Natale  – M. Calcagni Alenia Aerospazio – Divisione Aeronautica  MSC. Software S.r.l. – Italy Worldwide Aerospace Conference and Technology Showcase 2002

  2. necessity in developing tools of numerical simulation to evaluate in advance the critical points to decrease the global costs to reduce the number of tests to adopt the right production strategies NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR OBJECTIVES AND GOALS In the last years, more and more frequent utilization of the S.P.F. Worldwide Aerospace Conference and Technology Showcase 2002

  3. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR OBJECTIVES AND GOALS (CONT’D) • Tool chosen for the numerical simulation: MSC.Marc • Marc code applied to a concrete problem of the Alenia Aerospazio - Divisione Aeronautica: S.P.F. of the Under Carriage Door of the EF2000 • Steps followed: • numerical simulation of the S.P.F. process for the U/C Door • comparison between numerical and experimental readings of the door thickness • study of the simulation of the friction between die and forming plate • optimization of the loading curve • analysis and application of the new capabilities Marc • auto-adaptive remeshing Worldwide Aerospace Conference and Technology Showcase 2002

  4. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR SUPERPLASTICITY • S.P.F. : process able to produce very complex structures, based on the superplasticity of various kind of material • Superplasticity : particular state achieved by metals, alloys, ceramic materials in specific temperature and pressure conditions • In this state, possibility of undergoing very high deformation without necking • Condition to be verified to have superplastic state: • grains’ little dimensions (110 mm) • forming temperature higher than 50% fusion temperature • low deformation velocity • strain rate sensitivity factor at least equal to 0.3 Worldwide Aerospace Conference and Technology Showcase 2002

  5. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR S.P.F. SIMULATION FOR EF200 U/C DOOR • In the real process: • heated ( T= 485± 10°C) dies and presses are used; • initial plate thickness: 2.5 mm; • target strain rate=4*10-4 sec-1 • In the numerical simulation : • transfer of the die geometric model from CATIA by Direct Access CATIA • realization of the F.E.M. model of the plate to be formed • reproduction of the F.E.M. model of the die • application of the real loading curve and of the real constraints Worldwide Aerospace Conference and Technology Showcase 2002

  6. TEST U/C DOOR NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 Worldwide Aerospace Conference and Technology Showcase 2002

  7. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR F.E. MODELS OF THE PLATE AND OF THE DIE PLATE NODES : 14641 ELEMENTS : 14400 DIE GRIDS: 77576 SURFACES : 19394 Worldwide Aerospace Conference and Technology Showcase 2002

  8. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR MATERIAL CHARACTERIZING • Material isotropic and with a rigid-plastic law • Utilization of a law (Power law) with : A=0 • Bibliographic research to find the values of B ed n by curve at 505 °C : B=509.69 N*sec/mm2 n=0.65 Worldwide Aerospace Conference and Technology Showcase 2002

  9. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR LOADING AND CONSTRAINTS OF THE U/C DOOR MODEL • Real loading: hot pressurized air insufflated on the upper and on the lower part of the plate • Numerical loading: the real differential pressure has been applied to the plate • Constraints: edges of the plate clamped Worldwide Aerospace Conference and Technology Showcase 2002

  10. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION Worldwide Aerospace Conference and Technology Showcase 2002

  11. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION (CONT’D) Worldwide Aerospace Conference and Technology Showcase 2002

  12. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION (CONT’D) Worldwide Aerospace Conference and Technology Showcase 2002

  13. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR LOCATION OF THE EXPERIMENTAL AND NUMERICAL READINGS Worldwide Aerospace Conference and Technology Showcase 2002

  14. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR EXPERIMENTAL-NUMERICAL READINGS CORRELATION PART A Worldwide Aerospace Conference and Technology Showcase 2002

  15. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR EXPERIMENTAL-NUMERICAL READINGS CORRELATION PART B Worldwide Aerospace Conference and Technology Showcase 2002

  16. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR STUDY OF DIE - PLATE FRICTION • Non perfect agreement in few points of readings study of new MSC.Marc capabilities • Attention on a quick tool: the “test” of the door • Realization of a new detailed F.E.M. for the die and for the initial plate related to the test Worldwide Aerospace Conference and Technology Showcase 2002

  17. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR • Friction coefficient unknown parametric study by utilizing various friction coefficients STUDY OF DIE -PLATE FRICTION (CONT’D) • More reliable model of the friction (Coulomb friction): Ffr=mFn • Model of the friction available from Marc : Ffr=mFn2/p *arctan (Vr/RVCNST)*t • Choice of RVCNST so that the Coulomb friction has been used m = 0 m = 0.1 m = 0.25 m = 0.5 Worldwide Aerospace Conference and Technology Showcase 2002

  18. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY- m = 0 Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  19. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY- m = 0.1 Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  20. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY- m = 0.25 Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  21. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY- m = 0.5 Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  22. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY Numerical-Experimental thickness correlation Worldwide Aerospace Conference and Technology Showcase 2002

  23. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR STUDY OF OPTIMIZED LOADING CURVE • Operative application to improve the S.P.F. process: study of an optimized loading curve • By utilizing the new Marc capability, the loading curve is the main result • Necessity of indicating the direction, the versus of the loading and the maximum value of the pressure to be applied (p = 1N/mm2) • Choice of the “ending” termination Worldwide Aerospace Conference and Technology Showcase 2002

  24. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  25. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE Strain rates and V.M. stresses distribution Worldwide Aerospace Conference and Technology Showcase 2002

  26. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE Thickness distribution Worldwide Aerospace Conference and Technology Showcase 2002

  27. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE Strain rate distribution Worldwide Aerospace Conference and Technology Showcase 2002

  28. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING • Study of the new MSC.Marc capability to have a finer mesh in the critical zones • First level of remeshing Worldwide Aerospace Conference and Technology Showcase 2002

  29. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING Thickness and strain rate distribution Worldwide Aerospace Conference and Technology Showcase 2002

  30. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING Thickness and strain rate distribution Worldwide Aerospace Conference and Technology Showcase 2002

  31. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR SUMMARY OF THE TIME CALCULATION • Processor used: IBM RS/6000 449 Model 170 W/S - 1Gb of Ram 18 Gb of Internal Disk Drive Worldwide Aerospace Conference and Technology Showcase 2002

  32. NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR CONCLUSIONS • A study on the possibility of numerically simulating the S.P.F. has been performed • Numerical-experimental comparison demonstrates the opportunity of the Code MSC.Marc utilization like a good tool of numerical simulation • A study of simulation of die-plate friction has been performed • The capability of producing an optimized loading curve has been studied and applied • The capability of realizing an auto-adaptive remeshing has been explored • Advantages of a numerical simulation: • a more detailed knowledge of all the parameters of the process • possibility of knowing the optimized loading curve • numerical evaluation of the influence of the parameters on the process • reduction of the experimental tests • possibility of knowing the optimized thickness distribution of the initial plate Worldwide Aerospace Conference and Technology Showcase 2002

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