Precision Blank Development for Hydro-Formed Aerospace Components via Inverse Finite Element Analysis

The present article provides an abstract overview of the issue of optimal blank searching for integral parts utilized in complex engineering projects, including those pertaining to the fabrication of machine, ship, and aircraft components. The manufacturing process for these components is intricate and necessitates meticulous precision and strict adherence to the design model. Conventional blank calculation techniques are marred by substantial inaccuracies. The present research proposes and verifies an effective method based on the reverse solution of a mathematical problem. The focal point of this study is the aerodynamic curvature of aluminum alloys belonging to the Al–Mg–Mn family. The formation of the object is achieved through the employment of a hydroelastomer press of the QFC (Quintus Technologies) type. The forming process is simulated using PAM-STAMP software, developed by the French company ESI Group. The objective of the present study is to ascertain the optimal configuration of the blank by optimizing the discrepancy between the dynamic calculations and the design model using sweep contours. The resulting new shape of the part allows for the formation of parts with minimal deviation from their design contours.