Deharde Polygon Forming®

Deharde Polygon Forming® is an

innovative production technology for

forming of large sheet metals with

significant benefits in cost, quality and

time.

The technology is applicable for the

production of curved, twisted and conic

skins, doublers, straps etc. made of

metallic materials.

Safe cost, gain quality

Technical applications of Deharde Polygon Forming ™

The Deharde Polygon Forming®technology is able to create cylindrical, conical and twisted Skins.

R1 or R2 can be splines.

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Geometrics

R2

R1

Cylindrical skin with changing radii

Conical skin with different radii

Twisted skin with different radii

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Quality

No Mod No drawing-modification required

Variety Applicable for cylindrical, conical, twisted metallic skins, doublers, straps etc.

REACH Machining instead of chemical milling

No pizza No elongation of workpiece as caused by Roll Forming („Pizza-effect“)

100% Rejectfree quality and a perfect fit for following process steps

Qualified Airbus qualified according process AIPS 03-10-005

Complexity Less manufacturing complexity due to 3-axis –milling instead of 5-axis milling

Automation Integrable in automated sheet metal production line

50% Up to 50% cost saving vs. roll forming

The innovative Deharde Polygon Forming® at a glance

Substitution of 5-axis- by 3-axis-machining plus perfect assembly

Deharde Polygon Forming®

allows 3-axis maching which isfaster on cheaper machines

versus

Roll Forming

requires mainly 5-axis-machining which isslower on more expensive machines

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Key cost advantage

Deharde Polygon Forming® versus the usual forming of complex sheet metals

Criterion Deharde Polygon Forming ® „Traditional“ Roll Forming

Flexibility Variable Radius, cylindrical, conical, twisted

Cylindrical

Quality 100% NC-controlled springback behavior NC-controlled

Cost Always one forming loop Often several forming loops required

Pocketing and Drilling 100% in flat condition before forming, no „pizza-effect“ (length extension)

To be performed after forming, „pizza-effect“

Pocketing and Drilling Conventional milling machine is always sufficient

5-axis machining on fixation jig often required or chemical milling (REACH problematic)

Advantage: High Quality, Cost Efficiency and Repeatability

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Cutting, pocketing, drillingDeharde

Polygon Forming ®Quality check

- Machining in flat condition- Conventional milling- No cost for flexible tooling- Easy handling

- One forming loop- Qualified process- No shrinking or elongation- Numeric controlled process

- Nearly rejectfree quality- 100% repeatability- Perfect fit for following

assembly processes

Only two production steps of a machined and formed skin

Result: Precise Deharde polygon formed skins allow lean tooling concepts for skin assembly

Application exampleFor all skins, doubler, straps of this fuselage, the Deharde Polygon Forming ™ can be applied ready for assembly, including all pockets, tack holes and positioning holes.

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Description Value Remark

Maximum skin length 5.500 mm Extension to 12.000 mm possible

Maximum circumferential skin width 6.500 mm Extension possible

Achievable radius 50 mm to limitless

Skin thickness Up to 30 mm Aluminum

Tolerance < 0,2 mm

Production capacity >10.000 skins per year 3-shift operation

Loft type Single curved Douple curved in development

The key characteristics of the Deharde Polygon Forming®

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Analysis phase Test phase Realization phase

Step 1:Data analysis of customerproducts if DPF is applicable

Step 2:Deharde is providing a costcalculation for the analysis ofindividuell DPF business case

Step 3: Ordering of test-parts at Deharde. Deharde isproducing prototype parts at Deharde-facilities.

Customer can check theperfect fit in the assembly-process.

Step 4a: Transfer of skin production toDeharde.

Alternative:

Step 4b: Setup of own DPF-facility on customer premises.

We offer our customer a risk-free step-by-step approach to Deharde Polygon Forming (DPF)

Benefit: Risk-free analysis and implementation of innovation to earn the benefits of Deharde Polygon Forming

Marc Brestrich

Managing Partner

m.brestrich@deharde.de

Tel.: +49 4451 9133 572

Mobil: +49 151 1885 9132

Eilert Wilken

Head of Sales and Marketing

e.wilken@deharde.de

Tel.: +49 4451 9133 40

Mobil: +49 151 1885 9128

Your contact for further information

Sven Lautenbach

Technical Project Leader Aerospace

Deharde Polygon Forming®

s.lautenbach@deharde.de

Tel.: +49 4451 9133 809

Mobil: +49 162 939 785

ReferencesDeharde Polygon Forming®

Conical Skin with pocketing and holes milled on both sides

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Skin:Vega-C launcher

Dimensions: 600x1800x7,5mm

Material: 7075T6

High precision skins for bonding tests

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Skin:Bonding test

Material: 2024T3

Cylindrical Skin with pocketing and holes milled on both sides

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Dimensions: 2133x1022x3,4mm

Material: 2024T3

Cylindrical Skin with pocketing and holes milled on both sides

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Dimensions: 1300x3595x13mm

Facts: 13mm max thickness and 6mm min thickness

Material: 2024T3

Complex cylindrical Skin with pocketing and holes

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Current projectDimensions: 2438,4x2438,4x3,4mm

Material: 2024T3