A method for designing lightweight and flexible creep-age forming tools using mechanical splines and sparse controlling points

Creep-age forming (CAF) is a proven forming technique in the aerospace industry for the production of large integrally stiffened panels. One of the most urgent issues to be addressed in CAF is the development of flexible tooling. Flexible tools already have a long-standing reputation for the economic impact they have brought to the aircraft industry. However, with the rising need to establish comprehensive springback prediction models for CAF, the need for flexible CAF tools is now stronger than ever. In this article, an existing state-of-the-art CAF tool is described followed by the introduction of a novel design concept for flexible tooling. Based on the proposed design method, which utilises mechanical splines and sparsely spaced controlling points, a proof-of-concept prototype is built and characterised using corresponding analytical and finite element models that have been developed. Three parameters that can influence forming surface error: (i) the number of control points, (ii) spaces between control points and (iii) spline thickness are identified and optimised. Finally, an integrated optimisation process for tool offsetting is introduced, and its use is demonstrated. It is confirmed that this design method can be used to make flexible CAF tools with less than ± 1 mm error (defined as vertical difference from prediction) in the forming surface. In addition, this error can eventually be compensated and thus eliminated from CA-formed parts by using the developed optimisation technique. This article provides CAF tool designers confirmed advices for making new flexible CAF tools. Lightweight and flexible CAF tools can now be constructed through the use of mechanical splines and sparse controlling points.