Forming-based geometric correction methods for thin-walled metallic components: a selective review

Geometric correction processes contribute to zero-defect manufacturing for improved product quality. Thin-walled metallic components are widely used in numerous applications such as electric vehicles and aircraft due to the lightweight feature, facilitating to achieve zero-emission goals. However, many components suffer geometric imperfections and inaccuracies such as undesired curvatures and twists, seriously affecting subsequent manufacturing operations, for example, automatic welding and assembly. Geometric correction techniques have been established to address these issues, but they have drawn little attention in the scientific community despite their wide applications and urgent demands in the industry. Due to the strict geometric tolerances demanded in high-volume automated production, it is urgent to increase the knowledge needed to develop new techniques to address future industrial challenges. This review paper presents an overview of typical geometric defects in thin-walled components and clarifies the associated underlying generation mechanisms. Attempts have also been made to discuss and categorize geometric correction techniques based on different forming mechanisms. The challenges in correcting complex thin-walled products are discussed. This review paper also provides researchers and engineers with directions to find and select appropriate geometric correction methods to achieve high geometric accuracy for thin-walled metallic components.