Engineering Design Consultants

Airbus A380 Takes Creep Forming to New Levels

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Due to this process constraint, spring-back after CAF is very high compared to other metal forming processes, with up to 80% of the initial elastic deformation being recovered after processing.

The main benefits of creep forming are the accuracy and repeatability that can be achieved, as well as the ability to produce multiple curvatures on thick topologically complex components. Unlike shot peening, which can require several stages to achieve the required shape, CAF produces components that are very close to net shape in a single procedure. At Broughton, the process is also virtually automatic, requires little labour input and allows each wing skin to be processed in 24 hours to meet Airbus's throughput requirements.

The CAF process used at Broughton has three distinct phases. First, a fully machined flat wing skin panel is loaded and located by means of a guide system on to a generally concave form tool, whose surface has been designed to compensate for post-process spring-back. Next, a vacuum bag is fitted to seal the component against the continuous surface of the form tool, and air is removed from under the bag, creating an atmospheric pressure differential that produces a clamping action, forcing the panel towards the tool surface.