Case Studies and Applications of Flowforming to Aircraft Engine Component Manufacturing
Aircraft engine components are assemblies of several parts that are manufactured using various processes: deep drawing and machining, among others. Deep drawing cannot control accurately wall thicknesses and is performed in numerous steps. Machining parts from solids is less and less cost effective as prices for raw materials increase. Hence, the use of near net shape manufacturing methods is becoming more appealing. An alternative forming process is here investigated: flowforming, process well adapted to axisymmetric parts. The amount of forming steps, welding and machining could be significantly reduced, reducing lead-times and manufacturing costs. Examples are presented for the forming of selected parts (gas generator cases, fan cases and diverter ducts), together with their metallurgical and mechanical properties. Flowforming, however, can only generate shells with some hollow details: most flanges, bosses, stiffeners or weld lips cannot be obtained. Hence, methods of adding material are explored.
F. Micari, M. Geiger, J. Duflou, B. Shirvani, R. Clarke, R. Di Lorenzo and L. Fratini
J. Savoie and M. Bissinger, "Case Studies and Applications of Flowforming to Aircraft Engine Component Manufacturing", Key Engineering Materials, Vol. 344, pp. 443-450, 2007