Experimental Investigation of The Manufacturability of The Rear Cargo Door Actuation Cavity Component in Airbus A321 Aircraft Using Hydroforming Method with Al 2024 T3 Material

Abstract

Hydroforming is a process for shaping metal sheet materials using high-pressure fluid, which is gaining importance and becoming more widely used every day. Due to the incompressibility of liquids, the same pressure is applied at every point, allowing for the easier creation of complex shapes. This method enables the production of higher-strength parts as a single piece. It is possible to manufacture many components using hydroforming without the use of expensive tooling costs, additional expenses, and weight-adding fasteners. In this study, design and finite element method (FEM) analyses were performed for the production of the rear cargo door actuation cavity in Airbus A321 passenger aircraft, followed by mold design and production. Suitable shaping was achieved using fluid at a pressure of 1600 psi (110 bar). A commercial hand pump was used to obtain the required pressure. The material used was 1.2 mm thick Al 2024 T3. The produced sheet material was examined using non-destructive testing methods to ensure it met the necessary quality requirements. The results of the simulation and experimental studies of the product shaped by hydroforming were compared, and the results were found to be highly compatible. The study demonstrated that hydroforming technology could be used in the production of more complex workpieces that require higher strength, thanks to the more controllable and precise force application in later stages. Guiding results were obtained regarding material and pressure selection for the production of the rear cargo door actuation cavity in Airbus A321 passenger aircraft.

Keywords

• Hydroforming
• Sheet Metal Forming
• Tube Forming
• Forming with Liquids

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