Khodko O. The method of technological parameter setting for the hydrodynamic forming of pipe joints of aircraft air systems using integrated CAD/CAE-systems

The object is hydrodynamic forming (HDF) technological process of pipe joints for aircraft air systems; the aim is the development of the method for obtaining the technological parameter setting for the HDF of pipe joints for aircraft air systems using integrated CAD/CAE-systems; the methods are mathematical modelling, numerical methods for solving problems of deformation, fracture and fluid-structure interaction; the results are: the proposed method which allows us to numerically optimize the technological processes of manufacture of pipe joints for aircraft air systems at the design stage, and reduce material and time spent on their development and optimization; the method allows to assign the basic technological parameters of HDF, while minimizing energy demands, the number of forming stages and intermediate heat treatments, the load on the tooling and to obtain the rational pressure pulse parameters; the novelties are: it is proposed for the first time the method of technological parameter setting for the multistage HDF, which is based on a numerical model of the process; an advanced numerical model of HDF process have been developed, which allows us to take into account the shock wave propagation in the transmission medium, strain and strain-rate hardening, damage of the blank metal, elastic deformation of the die; a new method for determining the optimal power parameters of HDF by means of varying the piston weight and initial velocity have been proposed; further development of the practicality of using different technological methods for controlling the amplitude and time parameters of pressure pulse and the effect of these parameters on the quality of manufactured parts has been reached; degree of introduction – the results were sent to the «KhAI-Service» company for use in equipment modernization of the «Antonov» State Enterprise division of HDF, and used for training process at the National Aerospace University «Kharkiv Aviation Institute»; industry sector – aircraft manufacturing.