Until now, variable wall thicknesses of aircraft stringers have been produced by chemical etching – PtU has now developed an innovative rolling process that can apply the wall thickness gradients to the extruded T-profiles in a more environmentally friendly and resource-efficient way.

As part of the MeGro project, a rolling stand was developed entirely in-house, featuring a new type of roll configuration with translationally adjustable screw rolls. This configuration enables the simultaneous rolling of the web and flange of the T-profiles. After a long period of design, manufacture and assembly, the rolling stand is now ready for use!

By specifying control curves, the new rolling process can be used to apply the desired thickness gradients to the profiles in a targeted manner. Straightening measures have been identified and implemented to avoid profile bowing in the longitudinal direction. In addition to intensive numerical feasibility studies, the project focused on the successful implementation of the process in real operation.

The new process was realised as part of the ‘MeGro – Metallic Large Components’ (opens in new tab) project, funded by the Investitions- und Förderbank Niedersachsen. Our special thanks go to Airbus Aerostructures GmbH for the excellent cooperation!