Wrinkling Analysis and Process Optimization of the Hydroforming Processes of Uncured Fiber Metal Laminates for Aircraft Fairing Structures

Lightweight composite structures like fiber metal laminates (FMLs) are widely used to manufacture aircraft structures and substitute metallic parts. While the superior mechanical performance of FMLs, including their high specific strength and excellent impact and fatigue resistance, has gained the interest of many researchers in the aerospace manufacturing industry, there are still some challenges that need to be considered. Conventional approaches like lay-up techniques and autoclave molding can achieve the relatively simple FML parts with large radii and profiles required for aircraft fuselages and flat skins. However, these methods are not suitable for forming complex-shaped structural parts due to the limited failure strain of fiber-reinforced materials and complex failure modes of the laminates. This research puts forward a new methodology that combines the hydroforming and subsequent curing process to investigate the feasibility of manufacturing complex aircraft parts like fairings made by FMLs. In this research, wrinkle formations are analyzed under various parameters during the hydroforming process. The geometrical shape of the initial blanks and the parameters, including blank holder force and cavity pressure, have been optimized to avoid flange edge wrinkles, and the addition of local support materials contributes to improving local wrinkling in the sharp corners. A finite element model (FEM) taking material laws, interlayer contacts, and boundary conditions into account is used to predict the dynamic hydroforming process of the fiber metal laminate, and experimental works are carried out for its verification. It is expected that the proposed method will reduce both costs and time, as well as reducing laminate defects. Thus, this method offers great potential for future applications related to manufacturing complex-shaped aerospace parts.