Development of polygon forming processes for aerospace engineering

Development of polygon forming processes for aerospace engineering

Philipp Müller, Bernd-Arno Behrens, Sven Hübner, Jan Jepkens, Hendrik Wester, Sven Lautenbach

download PDF

Abstract. The focus of this research lays on the further development of the Polygon Forming Technology, which is already successfully used for cold forming components in the aerospace industry. One example is the fuselage shell of the Airbus Beluga XL. According to the current state of the art it is possible to incrementally form large cylindrical or conical fuselage components by Polygon Forming. With the use of so-called infills, the Polygon Forming process can also be used to form components with pockets milled in the initial plane state. The limits of this technology exclude the creation of spherical geometries, such as those used in the front or rear fuselage sections of aircrafts. Presently, such components are produced by more complex stretch forming processes, which result in a considerable amount of scrap. In this work, a tool is developed to replicate the Polygon Forming process on experimental scale at the Institute of Forming Technology and Machines (IFUM) for materials commonly used in aerospace engineering. In addition, a downscaled pre-test tool is developed to investigate different tool geometries for incremental spherical forming inexpensive and easy according to the method of rapid prototyping.

Sheet Metal, Aluminum, Polygon Forming

Published online 3/17/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Philipp Müller, Bernd-Arno Behrens, Sven Hübner, Jan Jepkens, Hendrik Wester, Sven Lautenbach, Development of polygon forming processes for aerospace engineering, Materials Research Proceedings, Vol. 25, pp 69-76, 2023


The article was published as article 9 of the book Sheet Metal 2023

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] J-P. Immarigeon, R.T. Holt, A.K. Koul, L. Zhao, W. Wallace, J.C. Beddoes, Lightweight materials for aircraft applications, Materials Characterization, Volume 35, Issue 1, pp. 41-67, 1995.
[2] T. Dursun, C. Soutis, Recent developments in advanced aircraft aluminium alloys, Materials & Design (1980-2015) Volume 56, pp. 862-871, 2014.
[3] D. Uffelmann, Take-Off für hochfestes Aluminium im Automobilbau, ATZextra Karosserie Werkstoffe (2010) H.10.
[4] DIN EN 515:2017-5: Aluminium und Aluminiumlegierungen – Halbzeug –Bezeichnung der Werkstoffzustände. Beuth Verlag, 2017
[5] W. Koehler, B. Plege, K.F. Sahm, N. Padmapriya, Metal Forming: Specialized Procedures for the Aircraft Industry, Reference Module in Materials Science and Materials Engineering, 2017.
[6] F. Vollertsen, A. Sprenger, J. Kraus, H. Arnet, Extrusion, channel, and profil bending: a review, Journal of Materials Processing Technology Volume 87, Issues 1–3, pp. 1-27, 1999.
[7] B. Heller, S. Chatti, M. Schikorra, A.E. Tekkaya, Blechbiegen. In: Siegert K. Blechumformung. VDI-Buch, Springer, Berlin, Heidelberg. S.141-221. 2015.
[8] E. Wilken, S. Lautenbach, H. Frerichs, et al.: Verfahren und Anordnung zur Formänderung eines Plattenartigen Werkstücks. WO2020/147935A1. 2020
[9] DIN 8586:2003-09: Fertigungsverfahren Biegeumformen – Einordnung, Unterteilung, Begriffe. Beuth Verlag, 2003
[10] Doege, E.; Behrens B.-A.: Handbuch Umformtechnik, 2. Auflage, Springer Verlag, Berlin, Heidelberg, 2010.
[11] Airbus, Commercial Aircraft, A320 | The most successful aircraft family ever,, access at 14.09.2022
[12] DIN EN 485-2: Aluminium and aluminium alloys–Sheet, strip and plate – Part 2: Mechanical properties; German version EN 485-2:2016+A1:2018
[13] Altan, T., Tekkaya, A. E.: Sheet Metal Forming – Processes and Applications, ASM International, 2012.