EP4289527A1 - Systèmes et procédés de matriçage - Google Patents

Systèmes et procédés de matriçage Download PDF

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Publication number
EP4289527A1
EP4289527A1 EP23177318.5A EP23177318A EP4289527A1 EP 4289527 A1 EP4289527 A1 EP 4289527A1 EP 23177318 A EP23177318 A EP 23177318A EP 4289527 A1 EP4289527 A1 EP 4289527A1
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EP
European Patent Office
Prior art keywords
die
metal blank
grid
stiffening ribs
skin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23177318.5A
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German (de)
English (en)
Inventor
Bryce T. Kelford
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rohr Inc
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Rohr Inc
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Filing date
Publication date
Application filed by Rohr Inc filed Critical Rohr Inc
Publication of EP4289527A1 publication Critical patent/EP4289527A1/fr
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/02—Producing blanks in the shape of discs or cups as semifinished articles for making hollow articles, e.g. to be deep-drawn or extruded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00—Making other articles

Definitions

  • the present disclosure relates generally to a process and apparatus for press coining and, more particularly, to a process and apparatus for closed-die press coining features into a metal blank.
  • Aeronautical and aerospace vehicles can be exposed to harsh environments. These vehicles are sometimes made with oxidation-corrosion-resistant materials well suited for service in harsh environments subjected to heat and/or pressure. Machining oxidation-corrosion-resistant materials can be difficult and time consuming due to the high material hardening rate and slow feed/speed often employed to avoid cutter wear and heat accumulation.
  • a system for press coining a metal blank comprises a first die configured to receive the metal blank, a second die configured to move toward the first die to compress the metal blank therebetween, and a plurality of discrete protrusions extending from a base surface of the second die and forming a grid structure in a negative space therebetween.
  • the grid structure comprises at least one of an isogrid or an orthogrid.
  • a side cross-section of each protrusion of the plurality of discrete protrusions comprises at least one of a tapered geometry or a rounded geometry.
  • a transverse cross-section of each protrusion of the plurality of discrete protrusions comprises at least one of a quadrilateral geometry or a triangular geometry.
  • the plurality of discrete protrusions comprises a first row of discrete protrusions, a second row of discrete protrusions spaced apart from the first row of discrete protrusions by a first distance, and a third row of discrete protrusions spaced apart from the second row of discrete protrusions by a second distance, wherein the first distance is equal to the second distance.
  • the base surface is a planar surface.
  • a ratio of the first distance and a width of a discrete protrusion of the plurality of discrete protrusions is between 1: 10 and 1:30.
  • the first die comprises a die recess extending into the first die from a top surface of the first die to a recess surface of the first die, and the metal blank is configured to be received at least partially into the die recess.
  • the top surface extends around a perimeter of the first die
  • the die recess extends longitudinally within the first die between opposing longitudinal sides of the recess surface
  • the die recess extends laterally within the first die between opposing lateral sides of the recess surface.
  • a method for forming a stiffened panel comprises moving a metal blank over a first die, wherein the metal blank comprises an initial thickness, moving a second die toward the second die, compressing the metal blank between the first die and the second die, wherein the second die comprises a plurality of discrete protrusions extending from a base surface of the second die and forming a grid structure in a negative space therebetween, and moving material of the metal blank from between the plurality of discrete protrusions and the first die to the grid structure, thereby forming the stiffened panel comprising a skin and a grid of stiffening ribs.
  • the skin has a skin thickness which is less than the initial thickness.
  • the grid of stiffening ribs has a rib height which is greater than the initial thickness.
  • the metal blank is a planar sheet prior to being compressed between the first die and the second die.
  • the initial thickness is between 0.05 inches and 0.50 inches.
  • the metal blank comprises an austenitic nickel-chromium-based alloy.
  • the method further comprises, subsequent to compressing the metal blank between the first die and the second die, removing material from the metal blank to achieve at least one of a desired rib width of the grid of stiffening ribs or a desired thickness of the skin.
  • the method further comprises, subsequent to removing material from the metal blank, compressing the grid of stiffening ribs to flare an end of each stiffening rib of the grid of stiffening ribs.
  • the method further comprises, heating the metal blank to a forging temperature prior to moving the metal blank over the first die.
  • a method for forming a stiffened panel comprises press coining a metal blank with a first die and a second die to form a skin and a grid of stiffening ribs extending from the skin, removing material from the metal blank to achieve at least one of a desired rib width of the grid of stiffening ribs or a desired thickness of the skin, and compressing the grid of stiffening ribs to flare an end of each stiffening rib of the grid of stiffening ribs.
  • the metal blank Prior to the press coining, the metal blank comprises an initial thickness. After the press coining and prior to removing the material, the skin has a skin thickness which is less than the initial thickness and the grid of stiffening ribs has a rib height which is greater than the initial thickness.
  • the method further comprises heating the metal blank to a forging temperature prior to press coining the metal blank.
  • the grid of stiffening ribs are compressed with a hydraulic press.
  • the metal blank comprises an austenitic nickel-chromium-based alloy.
  • references to "a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.
  • coating refers to a closed-die forging process, in which pressure is applied on the surface of a metal blank in order to obtain close tolerance surfaces.
  • Press coining systems and methods of the present disclosure may be used for forming integral (e.g., monolithic) stiffening ribs in a metal blank or sheet.
  • Press coining systems of the present disclosure include a first die (e.g., a bottom die) and a second die (e.g., a top die).
  • the second die comprises a plurality of discrete protrusions sized and spaced for pushing material outside an initial profile of the metal blank to form the integral stiffening ribs.
  • Press coining systems and methods of the present disclosure may reduce stiffened panel manufacturing time compared to traditional negative manufacturing methods (i.e., material removal processes) such as milling or grinding.
  • Press coining system 100 (also referred to herein as a press coining tool) for press coining a metal blank is schematically illustrated, in accordance with various embodiments.
  • Press coining system 100 includes a first die 102 (e.g., a bottom die) and a second die 104 (e.g., a top die) that together form a closed-die forging or coining tool.
  • a metal blank 110 such as a thin metal sheet, may be received by first die 102.
  • Second die 104 may be configured to move toward the first die 102 (e.g., via a hydraulic press or the like) to compress the metal blank 110 therebetween.
  • the second die 104 is configured with a plurality of discrete protrusions 118 extending toward first die 102 and forming a grid structure in the negative spaces therebetween.
  • the plurality of discrete protrusions 118 are formed integrally with (e.g., monolithic) the first die 102.
  • the grid structure is press coined into the metal blank to form the metal blank into a stiffened panel.
  • the metal blank 110 is made of a nickel superalloy such as an austenitic nickel-chromium-based alloy such as that sold under the trademark Inconel ® which is available from Special Metals Corporation of New Hartford, New York, USA.
  • a metal blank of the present disclosure may comprise a high strength austenitic nickel-chromium-based alloy, such as Inconel ® 718.
  • the metal blank of the present disclosure tends to be difficult and time-consuming to machine due to the high strength of the material.
  • metal blank 210 for use in the press coining system, according to various embodiments of the present disclosure.
  • metal blank 210 may be an example of the metal blank 110 described herein with respect to FIG. 1 and FIG. 6A through FIG. 6C .
  • the metal blank 210 extends longitudinally along a longitudinal centerline of the metal blank 210 (e.g., parallel to X-axis) between and to a first end 211 of the metal blank 210 and a second end 212 of the metal blank 210.
  • the metal blank 210 extends laterally (e.g., parallel to Y-axis) between and to a first side 213 of the metal blank 210 and a second side 214 of the metal blank 210.
  • the metal blank 210 extends vertically (e.g., parallel to Z-axis) between and to a bottom side 215 of the metal blank 210 and a top side 216 of the metal blank 210.
  • Metal blank 210 may be configured as a planar sheet of material.
  • Metal blank 210 may comprise an initial thickness 290.
  • initial thickness 290 is between 0.05 inches (0.127 cm) and 0.50 inches (1.27 cm), between 0.05 inches (0.127 cm) and 0.30 inches (1.762 cm), between 0.1 inches (0.254 cm) and 0.20 inches (0.508 cm), or between 0.14 inches (0.3556 cm) and 0.18 inches (0.4572 cm).
  • the initial thickness 290 is uniform throughout the metal blank 210.
  • first die 302 for use in the press coining system, according to various embodiments of the present disclosure.
  • first die 302 may be an example of first die 102 described herein with respect to FIG. 1 and FIG. 6A through FIG. 6C .
  • the first die 302 extends longitudinally along a longitudinal centerline of the first die 302 (e.g., parallel to X-axis) between and to a first end 311 of the first die 302 and a second end 312 of the first die 302.
  • the first die 302 extends laterally (e.g., parallel to Y-axis) between and to a first side 313 of the first die 302 and a second side 314 of the first die 302.
  • the first die 302 extends vertically (e.g., parallel to Z-axis) between and to a bottom side 315 of the first die 302 and a top side 316 of the first die 302.
  • the first die 302 is configured with at least one die recess 318; e.g., a pocket, a channel, a groove, a cavity, a depression, etc.
  • the die recess 318 of FIG. 3 extends (e.g., partially) vertically into the first die 302 from a top surface 317 of the first die 302 to a recess surface 319 of the first die 302, where the top surface 317 of FIG. 3 is arranged around the perimeter of the first die 302 at the top side 316.
  • the die recess 318 of FIG. 3 extends longitudinally in (e.g., within) the first die 302, for example, between opposing longitudinal sides of the recess surface 319.
  • the die recess 318 of FIG. 3 extends laterally in (e.g., within) the first die 302, for example, between opposing lateral sides of the recess surface 319.
  • the recess surface 319 may be a planar surface and may have a flat geometry.
  • the die recess 318 of FIG. 3 is configured to receive the metal blank.
  • second die 404a (referred to generally herein using reference numeral 404) for use in the press coining system, according to various embodiments of the present disclosure.
  • second die 404b may be an example of second die 104 described herein with respect to FIG. 1 and FIG. 6A through FIG. 6C .
  • the second die 404 extends longitudinally along a longitudinal centerline of the second die 404 (e.g., parallel to X-axis) between and to a first end 411 of the second die 404 and a second end 412 of the second die 404.
  • the second die 404 extends laterally (e.g., parallel to Y-axis) between and to a first side 413 of the second die 404 and a second side 414 of the second die 404.
  • the second die 404 extends vertically (e.g., parallel to Z-axis) between and to a bottom side 415 of the second die 404 and a top side 416 of the second die 404.
  • the second die 404 is configured with a plurality of discrete protrusions 418a (referred to generally herein using reference numeral 418) extending from a base surface 420 of the second die 404 and forming a grid structure 422a (referred to generally herein using reference numeral 422) in the negative spaces therebetween.
  • the base surface 420 may be at the bottom side 415 of the second die 404.
  • base surface 420 is a planar surface.
  • the plurality of discrete protrusions 418 are arranged into rows 424 (extending along the X-axis) and columns 426 (extending along the Y-axis).
  • each row 424 of discrete protrusions 418 is spaced apart from an adjacent row 424 of discrete protrusions by a distance 428.
  • the distance 428 is uniform throughout the rows 424 (i.e., each row 454 is equally spaced from the adjacent rows 424). In various embodiments, the distance 428 may vary depending on the desired local stiffening.
  • each column 426 of discrete protrusions 418 is spaced apart from an adjacent column 426 of discrete protrusions by a distance 429. In various embodiments, the distance 429 is uniform throughout the columns 426 (i.e., each column 426 is equally spaced from the adjacent columns 426). In various embodiments, the distance 429 may vary depending on the desired local stiffening.
  • each protrusion 418a comprises a square geometry.
  • a transverse cross-section (i.e., in the X-Y plane) of each protrusion 418a comprises a generally square geometry or a generally rectangular geometry.
  • each protrusion 418 comprises a tapered and/or rounded geometry.
  • side cross-section (i.e., in the X-Z plane and/or the Y-Z plane) of each protrusion 418 comprises a tapered geometry and/or a rounded geometry. Configuring each protrusion 418 with a tapered and/or rounded geometry may reduce strain in the metal blank during the press coining process.
  • the grid structure 422 is an orthogrid.
  • the metal blank 110 in response to being press coined, may be formed into a stiffened panel 510a comprising a skin 530a and a grid of stiffening ribs 540a.
  • the shape of the grid of stiffening ribs 540a may be similar (e.g., substantially the same) to the shape of the grid structure 422.
  • stiffening ribs 540a may be formed as an orthogrid.
  • second die 404b (referred to generally herein using reference numeral 404) for use in the press coining system, according to various embodiments of the present disclosure.
  • second die 404b may be an example of second die 104 described herein with respect to FIG. 1 and FIG. 6A through FIG. 6C .
  • each protrusion 418b comprises a triangular geometry.
  • a transverse cross-section (i.e., in the X-Y plane) of each protrusion 418b comprises a generally triangular geometry.
  • the grid structure 422b is an isogrid.
  • the metal blank 110 in response to being press coined, may be formed into a stiffened panel 510b comprising a skin 530b and a grid of stiffening ribs 540b.
  • the shape of the grid of stiffening ribs 540b may be similar (e.g., substantially the same) to the shape of the grid structure 422b.
  • stiffening ribs 540b may be formed as an isogrid.
  • second die 404c (referred to generally herein using reference numeral 404) for use in the press coining system, according to various embodiments of the present disclosure.
  • second die 404c may be an example of second die 104 described herein with respect to FIG. 1 and FIG. 6A through FIG. 6C .
  • each protrusion 418c comprises a square geometry.
  • a transverse cross-section (i.e., in the X-Y plane) of each protrusion 418c comprises a generally square geometry or a generally rectangular geometry.
  • the grid structure 422c is an anglegrid.
  • the metal blank 110 in response to being press coined, may be formed into a stiffened panel 510c comprising a skin 530c and a grid of stiffening ribs 540c.
  • the shape of the grid of stiffening ribs 540c may be similar (e.g., substantially the same) to the shape of the grid structure 422c.
  • stiffening ribs 540c may be formed as an isogrid.
  • die protrusions of the present disclosure may comprise other geometries, such as a parallelogram or a quadrilateral, for example.
  • each protrusion 418 of a particular die comprises the same geometry.
  • each protrusion 418 of a particular die comprises a combination of two or more geometries.
  • a second die 404d is illustrated having a plurality of protrusions 418d of various geometries and defining a grid structure 422d.
  • a press coining process is illustrated, in accordance with various embodiments.
  • a first die 102 may be disposed with respect to a second die 104.
  • a method for forming a stiffened panel includes moving a metal blank 110 over the first die 102 (see FIG. 6B ). Prior to being press coined, the metal blank comprises an initial thickness 290. Moreover, prior to moving the metal blank 110 over the first die 102, the metal blank 110 may be heated to a forging temperature.
  • the forging temperature is between 1200° F (649° C) and 2200° F (1204° C), between 1400° F (760° C) and 2000° F (1093° C), or between 1600° F (971° C) and 2200° F (1204° C).
  • the metal blank 110 installed over the first die 102 (e.g., disposed in the die recess 318, with momentary reference to FIG. 3 )
  • the second die 104 is moved toward the first die 102 (e.g., with a hydraulic press or the like) until the second die 104 contacts the metal blank 110.
  • the second die 104 may continue to be moved toward the first die 102 to compress the metal blank 110.
  • the material of the metal blank 110 located vertically (i.e., along the Z-axis) between the protrusions 118 and the first die 102 is pushed to the negative space between each of the protrusions 118 to form a skin 130 and a grid of stiffening ribs 140.
  • the material of the metal blank 110 may be extruded into the negative space between each of the protrusions 118 to form the ribs 140.
  • the material of the metal blank 110 is extruded into the negative space between each of the protrusions 118, the material is pushed outside the initial profile of the metal blank 110.
  • the press-coined thickness 292 of the skin 130 may be between 5% and 75% of the initial thickness 290 of the metal blank 110, between 10% and 50% of the initial thickness 290 of the metal blank 110, between 20% and 45% of the initial thickness 290 of the metal blank 110, or between 35% and 40% of the initial thickness 290 of the metal blank 110.
  • the press-coined rib height 294 of the ribs 140 is greater than the initial thickness 290. In various embodiments, the press-coined rib height 294 of the ribs 140 is between 100% and 200% of the initial thickness 290 of the metal blank 110, between 125% and 200% of the initial thickness 290 of the metal blank 110, between 145% and 180% of the initial thickness 290 of the metal blank 110, or between 155% and 170% of the initial thickness 290 of the metal blank 110.
  • stiffened panel 710 subsequent to being press coined using a press coining tool of the present disclosure is illustrated, in accordance with various embodiments.
  • stiffened panel 710 may be an example of metal blank 110 described herein with respect to FIG. 6C after being press coined into a stiffened panel.
  • the base of the ribs 740 may be rounded near the skin (e.g., at the intersection of the skin 730 and the ribs 740 due to the rounded or tapered shape of the protrusions (e.g., protrusions 118 of FIG. 6C ).
  • the rib width 786 is directly related to the distance between adjacent protrusions (e.g., see distance 428 and/or distance 429 in FIG. 4A ). In various embodiments, the ratio of rib width 786 to rib spacing 746 is between 1:5 and 1:35, between 1:10 and 1:25, or between 1:12 and 1:22. In various embodiments, the ratio of the rib height 784 to the skin thickness 782 is between 4:1 and 20:1, between 5:1 and 15:1, or between 7:1 and 13:1.
  • the ribs 740 and/or skin 730 may be machined to remove material therefrom to achieve a desired shape and/or size.
  • FIG. 7B schematically illustrates a machining tool 745 (e.g., a mill, a grinding wheel, or the like) removing material from stiffened panel 710 to achieve a desired shape and/or size.
  • FIG. 7B illustrates the machining tool 745 rotating about a centerline axis and translating along a horizontal axis (i.e., to the right in FIG. 7B as illustrated by the arrow).
  • the inner surface 732 of the skin 730 may be machined to achieve a desired final thickness 792.
  • the ends 742 of the ribs 740 may be machined to achieve a desired final rib height 794.
  • the sides 744 of the ribs 740 may be machined to achieve a desired final rib width 796.
  • the ribs 740 and/or skin 730 may be milled using an electro chemical milling tool 770 to remove material therefrom to achieve a desired shape and/or size.
  • Electro chemical milling tool 770 may comprise a non-conductive coating 771. In this manner, electrical current flow and/or conductive electrolyte flow may be directed at the end 772 of the electro chemical milling tool 770.
  • a plunge force, illustrated by arrows 773, may be applied to the electro chemical milling tool 770 during the electro chemical milling process to move the electro chemical milling tool 770 toward stiffened panel 710 to remove material therefrom.
  • the electro chemical milling tool 770 is moved only along the longitudinal axis (e.g., parallel to the direction of arrows 773 in FIG. 7C ) during the electro chemical milling process.
  • the stiffened panel 710 may undergo an upsetting process whereby the ribs 740 are compressed with a flat tool 804 (e.g., similar to second die 104 of FIG. 1 except without protrusions 118), in accordance with various embodiments.
  • the stiffened panel 710 is placed between a first tool 802 and the second tool 804 to compress the ribs 740 to a desired rib height.
  • the final rib height 894 of the ribs 740 is achieved in a controllable and precise manner.
  • the ends 742 of the ribs 740 are flared, thereby achieving a generally trapezoidal-shaped rib and benefiting from the structural integrity of a trapezoidal stiffener (i.e., similar to a T-shaped stiffener).
  • the upsetting process causes the ribs 740 to distort into a trapezoidal shape with a flared end 742 that tapers toward the skin 730.
  • the press coining tool 100 and its components 202, 204 are described above using the terms “bottom” and “top” with reference to exemplary orientations in the drawings. The present disclosure, however, is not limited to any particular formation system orientations.
  • the first die 202 may alternatively be configured as a top die and the second die 204 may alternatively be configured as a bottom die.
  • references to "one embodiment,” “an embodiment,” “various embodiments,” etc. indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
  • Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure.
  • a stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result.
  • the stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
  • the terms “substantially,” “about” or “approximately” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result.
  • the term “substantially,” “about” or “approximately” may refer to an amount that is within 10% of, within 5% of, within 1% of, within 0.1% of, and within 0.01% of a stated amount or value

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
EP23177318.5A 2022-06-07 2023-06-05 Systèmes et procédés de matriçage Pending EP4289527A1 (fr)

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US17/834,814 US20230390823A1 (en) 2022-06-07 2022-06-07 Press coining systems and methods

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0334976A1 (fr) * 1984-09-06 1989-10-04 Joseph J. Mele Appareil pour façonner des pièces métalliques par fluo-forgeage et former des tôles métalliques à l'aide de matériau élastique
US8535783B2 (en) * 2010-06-08 2013-09-17 United Technologies Corporation Ceramic coating systems and methods
FR3109364B1 (fr) * 2020-04-17 2022-04-08 Latecoere Procédé de fabrication d’une porte d’aéronef monolithique par matriçage et usinage

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0334976A1 (fr) * 1984-09-06 1989-10-04 Joseph J. Mele Appareil pour façonner des pièces métalliques par fluo-forgeage et former des tôles métalliques à l'aide de matériau élastique
US8535783B2 (en) * 2010-06-08 2013-09-17 United Technologies Corporation Ceramic coating systems and methods
FR3109364B1 (fr) * 2020-04-17 2022-04-08 Latecoere Procédé de fabrication d’une porte d’aéronef monolithique par matriçage et usinage

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