Search

A thermoplastic matrix composite flat panel stiffened by induction welded stringers, according to a typical aerospace configuration was tested. A Poly-Ether-Ether-Ketone (PEEK) matrix reinforced by carbon fibers was adopted. The aim of this study was to investigate the shear buckling, a load condition that is very common for the aerospace structures, of the panel obtained using a non-conventional approach for its fabrication, that is, induction welding. A finite element (FE) model capable to describe the buckling and the postbuckling behavior of the stiffened panel was also developed and compared with experimental results. Testing was performed using fixtures suitably designed to transmit a pure shear to the panel, and strain gauges were mounted on the external surfaces to measure the deformations.

Incremental sheet forming represents a relatively new process appointed to form sheets of pure metals, alloys, polymers, and composites for the manufacture of components in fields where customized production in a short time and at a low cost is required. Its most common variant, named single-point incremental forming, is a flexible process using very simple tooling; the sheet is clamped along the edges and a hemispherical-headed tool follows a required path, to deform the sheet locally. In so doing, better formability is reached without any dedicated dies and for low-forming forces, which represent some of the attractive features of this process. Nevertheless, and with special reference to thermoplastic sheets, incremental formed parts suffer from peculiar defects like twisting and wrinkling. In this numerical work, analyses were conducted through a commercial finite element code by varying the toolpath strategy of the incremental forming of polycarbonate sheets. The investigation of some features like the forming forces, the deformation states, the energy levels, and the forming time was carried out, to determine the toolpath strategy able to optimize the incremental forming process of polymer sheets. The results of the numerical analyses highlight a reduction of the forming forces when using toolpaths alternating diagonal up and vertical down steps and, presumably, a reduced risk of failures and defects. Furthermore, these toolpath strategies solutions also have a positive impact on the environment in terms of energy and do not significantly increase the manufacturing time.