Simulation and Validation of an Incremental Bending Process for Cylindrical Fuselage Components

authored by: Jan Jepkens, Philipp Müller, Hendrik Wester, Sven Hübner, Simon Wehrmann, Bernd-Arno Behrens
Abstract: In the aviation industry, a large number of processes are not digitalised. Simultaneously, many special processes are used in production, such as incremental bending. In order to model and efficiently design multi-stage processes with methods such as FEM, automation and linking of the individual simulations are necessary. This paper therefore presents a method for automatically simulating and evaluating a complete incremental bending process with 24 strokes in LS-Dyna using a Python framework with cfiles. The final validation of the force–displacement relationships and inner radii of the generated scaled fuselage shell show high prediction accuracies of about 90%. Thus, the presented methodology enables a FEM-based process design of incremental bending in the aviation industry.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Aerospace
Volume: 11
Publication date: 24.12.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Aerospace Engineering
Electronic version(s): https://doi.org/10.3390/aerospace11010014 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{8b6d801b0c104f758f73d841e5e485d4,
title = "Simulation and Validation of an Incremental Bending Process for Cylindrical Fuselage Components",
abstract = "In the aviation industry, a large number of processes are not digitalised. Simultaneously, many special processes are used in production, such as incremental bending. In order to model and efficiently design multi-stage processes with methods such as FEM, automation and linking of the individual simulations are necessary. This paper therefore presents a method for automatically simulating and evaluating a complete incremental bending process with 24 strokes in LS-Dyna using a Python framework with cfiles. The final validation of the force–displacement relationships and inner radii of the generated scaled fuselage shell show high prediction accuracies of about 90%. Thus, the presented methodology enables a FEM-based process design of incremental bending in the aviation industry.",
keywords = "FE multi-stage automation, fuselage shells, incremental bending, lightweight",
author = "Jan Jepkens and Philipp M{\"u}ller and Hendrik Wester and Sven H{\"u}bner and Simon Wehrmann and Bernd-Arno Behrens",
note = "This research was funded by the Investitions- und F{\"o}rderbank Niedersachsen—NBank, grant number ZW1-80159743.",
year = "2023",
month = dec,
day = "24",
doi = "10.3390/aerospace11010014",
language = "English",
volume = "11",
journal = "Aerospace",
issn = "2226-4310",
publisher = "Multidisciplinary Digital Publishing Institute (MDPI)",
number = "1",
}