1. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 1 MSC.SOFTWARE WORLDWIDE AEROSPACE CONFERENCE and TECHNOLOGY SHOWCASE TOULOUSE, April 8-10, 2002 Numerical simulation of the Super Plastic Forming Process of the EFA – 2000 Under Carriage Door F. Giordano  – A. Natale  – M. Calcagni  Alenia Aerospazio – Divisione Aeronautica MSC. Software S.r.l. – Italy

2. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 2 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR OBJECTIVES AND GOALS In the last years, more and more frequent utilization of the S.P.F. to evaluate in advance the critical points to adopt the right production strategies to reduce the number of tests to decrease the global costs necessity in developing tools of numerical simulation

3. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 3 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR OBJECTIVES AND GOALS (CONT’D)  analysis and application of the new capabilities Marc  Tool chosen for the numerical simulation: MSC.Marc  comparison between numerical and experimental readings of the door thickness  numerical simulation of the S.P.F. process for the U/C Door  Steps followed:  Marc code applied to a concrete problem of the Alenia Aerospazio - Divisione Aeronautica: S.P.F. of the Under Carriage Door of the EF2000  auto-adaptive remeshing  study of the simulation of the friction between die and forming plate  optimization of the loading curve

4. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 4 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR SUPERPLASTICITY  S.P.F. : process able to produce very complex structures, based on the superplasticity of various kind of material  Condition to be verified to have superplastic state:  grains’ little dimensions (1  10  m)  forming temperature higher than 50% fusion temperature  low deformation velocity  strain rate sensitivity factor at least equal to 0.3  In this state, possibility of undergoing very high deformation without necking  Superplasticity : particular state achieved by metals, alloys, ceramic materials in specific temperature and pressure conditions

5. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 5 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR S.P.F. SIMULATION FOR EF200 U/C DOOR  heated ( T= 485± 10°C) dies and presses are used;  initial plate thickness: 2.5 mm;  target strain rate=4*10 -4 sec -1  transfer of the die geometric model from CATIA by Direct Access CATIA  realization of the F.E.M. model of the plate to be formed  reproduction of the F.E.M. model of the die  application of the real loading curve and of the real constraints  In the real process:  In the numerical simulation :

6. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 6 U/C DOOR EF2000 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST U/C DOOR

7. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 7 F.E. MODELS OF THE PLATE AND OF THE DIE NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR DIE GRIDS: 77576 SURFACES : 19394 PLATE NODES : 14641 ELEMENTS : 14400

8. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 8 MATERIAL CHARACTERIZING  Utilization of a law (Power law) with : A=0  Bibliographic research to find the values of B ed n  Material isotropic and with a rigid-plastic law NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR by curve at 505 °C : B=509.69 N*sec/mm 2 n=0.65

9. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 9 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR LOADING AND CONSTRAINTS OF THE U/C DOOR MODEL  Numerical loading: the real differential pressure has been applied to the plate  Constraints: edges of the plate clamped  Real loading: hot pressurized air insufflated on the upper and on the lower part of the plate

10. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 10 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION

11. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 11 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION (CONT’D)

12. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 12 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR RESULTS OF MSC.Marc ANALYSIS HISTORY OF THE THICKNESS DISTRIBUTION (CONT’D)

13. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 13 LOCATION OF THE EXPERIMENTAL AND NUMERICAL READINGS NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR

14. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 14 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR EXPERIMENTAL-NUMERICAL READINGS CORRELATION PART A

15. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 15 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR EXPERIMENTAL-NUMERICAL READINGS CORRELATION PART B

16. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 16 STUDY OF DIE - PLATE FRICTION NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR  Non perfect agreement in few points of readings study of new MSC.Marc capabilities  Attention on a quick tool: the “test” of the door  Realization of a new detailed F.E.M. for the die and for the initial plate related to the test

17. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 17 STUDY OF DIE -PLATE FRICTION (CONT’D) F fr =  F n 2/  *arctan (V r /RVCNST)*t  = 0  = 0.1  = 0.25  = 0.5 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR  More reliable model of the friction (Coulomb friction): F fr =  F n  Model of the friction available from Marc :  Choice of RVCNST so that the Coulomb friction has been used  Friction coefficient unknown parametric study by utilizing various friction coefficients

18. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 18 TEST OF THE DOOR FRICTION PARAMETRIC STUDY-  = 0 Thickness distribution NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR

19. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 19 TEST OF THE DOOR FRICTION PARAMETRIC STUDY-  = 0.1 Thickness distribution NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR

20. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 20 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY-  = 0.25 Thickness distribution

21. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 21 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY-  = 0.5 Thickness distribution

22. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 22 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR TEST OF THE DOOR FRICTION PARAMETRIC STUDY Numerical-Experimental thickness correlation

23. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 23 STUDY OF OPTIMIZED LOADING CURVE NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR  Operative application to improve the S.P.F. process: study of an optimized loading curve  By utilizing the new Marc capability, the loading curve is the main result  Necessity of indicating the direction, the versus of the loading and the maximum value of the pressure to be applied (p = 1N/mm 2 )  Choice of the “ending” termination

24. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 24 U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE Thickness distribution NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR

25. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 25 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR Strain rates and V.M. stresses distribution U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE

26. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 26 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR Thickness distribution U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE

27. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 27 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR Strain rate distribution U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE

28. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 28 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING  Study of the new MSC.Marc capability to have a finer mesh in the critical zones  First level of remeshing

29. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 29 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR Thickness and strain rate distribution U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING

30. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 30 NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR Thickness and strain rate distribution U/C DOOR EF2000 STUDY OF THE OPTIMIZED LOADING CURVE WITH AUTO-ADAPTIVE REMESHING

31. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 31 SUMMARY OF THE TIME CALCULATION NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR  Processor used: IBM RS/6000 449 Model 170 W/S - 1Gb of Ram 18 Gb of Internal Disk Drive

32. PAGE AEROSPAZIO Divisione Aeronautica Worldwide Aerospace Conference and Technology Showcase 2002 32 CONCLUSIONS NUMERICAL SIMULATION OF THE S.P.F. PROCESS OF THE EFA - 2000 UNDER CARRIAGE DOOR  A study on the possibility of numerically simulating the S.P.F. has been performed  Numerical-experimental comparison demonstrates the opportunity of the Code MSC.Marc utilization like a good tool of numerical simulation  A study of simulation of die-plate friction has been performed  The capability of producing an optimized loading curve has been studied and applied  The capability of realizing an auto-adaptive remeshing has been explored  Advantages of a numerical simulation:  a more detailed knowledge of all the parameters of the process  possibility of knowing the optimized loading curve  numerical evaluation of the influence of the parameters on the process  reduction of the experimental tests  possibility of knowing the optimized thickness distribution of the initial plate