Development of Manufacturing Method for Truss Core Panel Based on Origami-Forming

2015 ◽  
Author(s):  
Hoan Thai Tat Nguyen ◽  
Phuong Thao Thai ◽  
Bo Yu ◽  
Ichiro Hagiwara
Keyword(s):  
Forming Process ◽  
Robot System ◽  
Cutting Method ◽  
Manufacturing Method ◽  
Truss Core ◽  
Equivalent Bending Stiffness ◽  
Lightweight Structure ◽  
Partition Method ◽  
In Fire ◽  
Honeycomb Panel

Although honeycomb panel is widely used in various stages, its adhesive for gluing honeycomb core and plate may burn by fire, leading to the requirement of another lightweight and high stiffness panel. Recently, an Origami structure called Truss Core Panel (TCP) is known as a lightweight structure that has equivalent bending stiffness as honeycomb panel, and safer in fire. However, some difficulties are found in forming TCP in general. In this study, a new forming process of TCP based on origami-forming is developed. In particular, the TCP is partitioned into several parts that are flat unfoldable into 2D crease patterns. After that, blanks of material are cut as the shapes of those crease pattern, and be formed by a robot system to get the desired 3D shape. Firstly, partition method by dividing TCP into pyramid cores and sheet plate is presented, suggesting an ability to manufacture a wider range of structure than before. Tools arrangement of robot device and a countermeasure for springback are considered. Next, by applying Origami unfolding technique, an improvement of partition method is proposed: dividing TCP into cores rows, and then searching for a Origami crease pattern in order to fold that cores row. The cutting method of every core is modified for reducing the number of facets, making the problem simpler. Finally, an Origami crease pattern based on this new cutting method is presented, producing cores row with any number of cores.

Development of a Manufacturing Method for Truss Core Panels Based on Origami-Forming

2016 ◽  
Vol 8 (3) ◽  
Author(s):  
Hoan Thai Tat Nguyen ◽  
Phuong Thao Thai ◽  
Bo Yu ◽  
Ichiro Hagiwara
Keyword(s):  
Compressive Load ◽  
Honeycomb Structure ◽  
Forming Process ◽  
Robot System ◽  
Cutting Method ◽  
Manufacturing Method ◽  
Truss Core ◽  
Lightweight Structure ◽  
Partition Method ◽  
Honeycomb Panel

Sandwich panels, for example, honeycomb structure, are widely used in various stages because they are lightweight and have high stiffness. Recently, an origami structure called truss core panel (TCP) has become known as a lightweight structure that has the same bending stiffness and better aspects in shear strength and in-plane compressive load than honeycomb panel. However, there are some difficulties in forming the TCP in general. In this study, a new forming process for TCP based on origami-forming is developed. In particular, the TCP is partitioned into several parts that can be developed into 2D crease patterns. After that, blanks of material are cut in the shape of these crease patterns and are formed by a robot system to get the desired 3D shape. In this paper, a partition method by dividing the TCP into pyramid cells and sheet plate is presented, which allows for the manufacture of a wider range of structure than before. Tool arrangement for a robot device and a countermeasure for springback are considered. By applying an origami unfolding technique, an improvement in the partition method is proposed by dividing the TCP into cell rows, and then searching for a crease pattern in order to fold that cell row. The cutting method of every cell is modified to reduce the number of facets, thereby simplifying the process. Finally, a crease pattern based on this new cutting method is presented for producing cell rows with any given number of cells.

scholarly journals Forming Process Simulation of Truss Core Panel

2010 ◽  
Vol 4 (1) ◽  
pp. 25-35 ◽  
Author(s):  
Sunao TOKURA ◽  
Ichiro HAGIWARA
Keyword(s):  
Process Simulation ◽  
Forming Process ◽  
Truss Core

Superplastic Blow Forming of Aerospace Components

2014 ◽  
Vol 622-623 ◽  
pp. 819-822
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo
Keyword(s):  
Elevated Temperature ◽  
Structural Integrity ◽  
Superplastic Forming ◽  
Forming Process ◽  
Turbine Engine ◽  
Manufacturing Method ◽  
Aerospace Applications ◽  
Wide Range ◽  
Bonded Joint ◽  
Near Net Shape

Many metals, such as titanium and superalloys, are used for a wide range of aerospace applications, which include aircraft gas turbine engine and space launcher propulsion engine. In order to manufacture a stiffened extension with superplastic blow forming at elevated temperature, the structural integrity of the joint part was investigated since the welded or bonded joint of internal channels should maintain its strength during superplastic blow forming process. Various types of joint methods were performed in order to investigate microstructural and mechanical properties of the bonded specimen at elevated temperature. In this paper, the possibility of manufacturing combustion chamber and other aerospace components with superplastic blow forming of titanium and superalloy was demonstrated. An innovative manufacturing method to produce complex configuration from titanium multi-sheets by superplastic forming with low hydrostatic pressure was presented. The result also shows that the manufacturing method with superplastic blow forming of multi-sheets of IN718 alloy has been successfully demonstrated for near net shape forming of subscale nozzle extension cone with internal channels.

Driving – A Flexible Manufacturing Method for Individualized Sheet Metal Products

2010 ◽  
Vol 447-448 ◽  
pp. 795-800
Author(s):  
Daniel Scherer ◽  
Z. Yang ◽  
H. Hoffmann
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Flexible Manufacturing ◽  
Incremental Forming ◽  
Industrial Robot ◽  
General Information ◽  
Work Piece ◽  
Forming Process ◽  
Manufacturing Method ◽  
Metal Products

This paper provides general information about the qualification of driving as an on-demand manufacturing concept for the production of individualized sheet metal products. Driving allows the creation of almost any 2D or 3D geometry, but it is a highly interactive, manual production process. Due to the inevitable variations of the incremental forming process (mechanical properties, tribology, wear etc.) and the high number of forming steps, it cannot be automated by traditional approaches. At the Institute of Metal Forming and Casting (Technische Universitaet Muenchen) a kraftformer machine has been equipped with measuring and controlling instrumentation. An optical online measurement system is installed to detect any geometry deformation of the current work piece and to visualize the deviation between the actual and the stored reference geometry during the whole production process. This variance comparison is the first step for planning any following incremental forming actions based on acquired and/or learned knowledge. The second step is the integration of an industrial robot for work piece handling and the automation of the whole manufacturing process. The last step is the integration of neural networks to predict production strategies for any desired unique geometry.

Metallic Bipolar Plate Fabrication Process of Fuel Cell by Rubber Pad Forming and its Performance Evaluation

2013 ◽  
Vol 535-536 ◽  
pp. 310-313 ◽  
Author(s):  
Min Geun Jung ◽  
Yong Phil Jeon ◽  
Chung Gil Kang
Keyword(s):  
Fuel Cell ◽  
Fossil Fuels ◽  
Bipolar Plate ◽  
Metal Plate ◽  
Proton Exchange ◽  
High Rate ◽  
Heat Of Reaction ◽  
Forming Process ◽  
Manufacturing Method ◽  
Rubber Pad Forming

Recently, the demand for energy is growing at a very high rate all over the world. The fossil fuels eventually lead to the foreseeable depletion of limited fossil energy resources. Hydrogen is considered a promising candidate to remedy the depletion of fossil fuels. The bipolar plate is the second most important component of a proton exchange membrance (PEM) fuel cell stack after the membrance electrode assembly (MEA). Its primary roles are to supply reactant gases to the fuel cell electrodes and provide electrical connection between adjacent cells in the stack while removing product water from the cell and transferring away the heat of reaction. Historically, machined graphite had been chosen as a good compromise between all of these requirements, but alternatives are emerging. New materials are light metals. In this study, rubber pad forming process was employed as the manufacturing method for metallic bipolar plates. The rubber pad and the sheet metal plate were pressed together by the punch, and the repulsive force of the deformed rubber is loaded at the plate, and can contribute to improving formability. And then, its surface was coated with TiN. After coating process, the performance characteristics of single stack in the condition of PEMFC using the metal bipolar plate have been investigated.

An Experimental Investigation on Profile Forming of an End Cap Using Al 3003 (O)

2011 ◽  
Vol 291-294 ◽  
pp. 549-555 ◽  
Author(s):  
S.P Shanmuganatan ◽  
V.S Senthil Kumar
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Forming Process ◽  
Microstructural Characteristics ◽  
Wall Angle ◽  
Manufacturing Method ◽  
Aluminium Sheet ◽  
Tool Profile ◽  
Metal Forming Process ◽  
Cylindrical Cup

The feasibility of using modern computers in manufacturing has evolved an era in the development of several new sheet metal forming process. The concept of profile forming technique has been investigated for production of sheet metal components. Profile forming is a very promising technology to manufacture sheet metal producs by CNC controlled movement with simple forming tool. Profile forming was developed as a flexible, alternative manufacturing method to effectively prototype stampings and produce in small lots. Cylindrical Cup is formed on Aluminium sheet of grade Al 3003 (O) without using punch and die. Formability of material, maximum wall angle, Surface roughness, thinning of sheet and Microstructural characteristics of Aluminium sheet are studied.

A Study for the Influence of Work Hardening on Bending Stiffness of Truss Core Panel

2010 ◽  
Vol 77 (3) ◽  
Author(s):  
Sunao Tokura ◽  
Ichiro Hagiwara
Keyword(s):  
Work Hardening ◽  
Bending Stiffness ◽  
Wall Material ◽  
Equivalent Stiffness ◽  
Honeycomb Core ◽  
Thickness Change ◽  
Three Point Bending ◽  
Truss Core ◽  
Shell Formulation ◽  
Honeycomb Panel

Honeycomb panel is widely used as flooring or wall material in various structures, e.g., buildings, aircraft, flooring members of railway car, and so on, due to high stiffness and lightness at present. Honeycomb panel, however, has a disadvantage that the adhesive used to glue honeycomb core and top plate may burn by fire. On the other hand, truss core panel has equivalent stiffness as honeycomb panel and is expected to be an alternative to honeycomb panel as it is safer for fire. To replace honeycomb panel with truss core panel, it is necessary to investigate the stiffness of truss core panel for bending, shear, compression, and so on. The bending case with a three-point bending model of truss core panel is chosen here. Four cases of analysis with/without work hardening effect and thickness change using two types of shell formulation are performed. These cases are compared with an equivalent honeycomb model. The study showed the effect of work hardening is very important to assess bending stiffness of truss core panel. It is also observed that the use of suitable shell formulation is necessary to obtain reliable result. In addition, the truss core panel shows bending stiffness comparable with conventional honeycomb panel.

Theoretical and experimental investigation of shaping process of circular metal tubes into triangular columns by the elastoforming method

2016 ◽  
Vol 231 (4) ◽  
pp. 658-674 ◽  
Author(s):  
Abbas Niknejad ◽  
Seyed Ghaem Amirhosseini ◽  
Nader Setoudeh
Keyword(s):  
Wall Thickness ◽  
Deformation Mode ◽  
Dissipated Energy ◽  
Theoretical Formula ◽  
Forming Process ◽  
Flat Punch ◽  
Manufacturing Method ◽  
Circular Tubes ◽  
Shaping Process ◽  
Different Characteristics

In this article, a new manufacturing method is introduced to shape circular tubes into columns with triangular cross-section by the elastoforming process. Also, a theoretical analysis is performed to derive a theoretical formula for predicting total dissipated energy that is required for the forming process. For this purpose, V-shape dies with different angles are designed and some aluminum and brazen tubes with different characteristics are prepared. The circular tubes in the empty and filled conditions are compressed between a rigid V-shape die and a flat punch, and during the plastic deformation under the lateral loading, the tubes are shaped into the triangular sections. Considering different tube lengths, outer diameters and wall thicknesses, the specimens are categorized. Also, some of the samples are filled by cylindrical polyethylene Teflon with different thicknesses to investigate the effects of Teflon-filler on the shaping process of the triangular columns. The experiments show that using the cylindrical Teflon-filler, deformation mode of the triangular tubes improves, significantly. In addition, experimental observations of the deformation modes illustrate that there is an optimum value for wall thickness of cylindrical Teflon-filler and the tubes with the optimum Teflon-filler forms close to desirable triangular shape. The results show that by increasing tube wall thickness, probability of crack initiation and fracture reduces. Furthermore, comparison of estimations by the presented theory and the corresponding experimental measurements show an acceptable agreement, in both of empty and filled conditions.

Development of Grooving Technique for Origami-Forming

2015 ◽  
Author(s):  
Hoan Thai Tat Nguyen ◽  
Kousuke Terada ◽  
Sunao Tokura ◽  
Ichiro Hagiwara
Keyword(s):  
New Method ◽  
Hard Material ◽  
Robot System ◽  
Handling System ◽  
Manufacturing Method ◽  
Large Pressure ◽  
Increase Risk ◽  
Reconfigurable Robot ◽  
Low Volume ◽  
Gauss Distribution

Recently, a new manufacturing method called Origami-forming is developed, based on traditional Origami approach. In particular, the new method follows the same steps as Origami, applying for wider rank of material (soft and hard material such as aluminum, high tensile steel, etc), and folding by a reconfigurable robot system. This method is suitable for high-variety low-volume, because of the unnecessary of die and punches. However, achieving the goal is still a challenge for researchers. Bending of hard material causes springback, increase risk of cracking, and require large pressure. In this study, by mimicking from the traditional Origami that we should make crease line before folding, bending method by grooving at the bend-line is proposed to reduce the necessary force to constraint the blank and get a high limit of bending. Firstly, several shapes of groove are compared: half-circle, gauss distribution, half-haxegon and rectangle. Then based on the comparison, the optimization of the shape is investigated. Lastly, handling system is considered to find an effective way of grasping the blank.

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