The application of aluminum plate hyperbolic in complex curved architectural structures hinges on achieving high-precision molding through digital design and precision machining technologies, while simultaneously controlling stress distribution by optimizing material properties and processes. This process spans the entire workflow from 3D modeling to on-site installation, requiring collaboration across multiple stages to achieve a balance between architectural aesthetics and structural safety.
3D modeling and parametric design are fundamental to aluminum plate hyperbolic molding. When architects construct curved surface models using software such as BIM or Rhino, they must refine the hypercurvature parameters to the millimeter level, ensuring that the radius of curvature and arc variations of each panel conform to the overall design requirements. Parametric design technology automatically generates panel splicing logic, reducing the number of irregularly shaped panels and lowering processing difficulty through algorithmic optimization. For example, the streamlined roof of Beijing Daxing International Airport utilizes this technology, controlling the error of tens of thousands of hyperbolic aluminum panels within ±0.5mm, achieving a natural and smooth transition between curved surfaces.
The mold design and verification stages directly impact molding accuracy. Traditional wooden or steel molds, due to their fixed curvature, are only suitable for mass production of sheets of the same specifications. Multi-point forming presses, however, adjust the pressure distribution through a discrete lattice, enabling dynamic mold adaptation to meet the needs of small-batch production with varying curvatures. For complex hyperboloids, a five-axis CNC machining center is required to directly carve the mold. Its high-degree-of-freedom motion axes can accurately replicate the surface features in the 3D model, avoiding the accumulation of errors caused by manual mold adjustments.
The choice of forming process must consider both material properties and curvature requirements. Hot stretching forms a large-curvature hyperboloid by heating the aluminum sheet to its plastic temperature range and stretching it with a mold, suitable for large-area shapes such as roofs. Cold stretching forms the sheet gradually through mechanical force at room temperature, making it more suitable for small-sized components with high strength requirements. Compression forming relies on high-precision molds to apply pressure to the aluminum sheet, directly forming complex surfaces, but requires custom molds for each curvature, resulting in higher costs. In actual production, multiple processes are often combined, such as initial cold stretching for preliminary forming, followed by compression molding to refine local details, balancing efficiency and accuracy.
Stress control is a key challenge in the processing of aluminum plate hyperbolic materials. During bending, aluminum is prone to residual stress due to plastic deformation, leading to springback or cracking. To address this issue, stress-relief annealing is necessary after forming. By controlling the heating temperature and holding time, the internal grains of the material rearrange, eliminating processing stress. Furthermore, using a progressive stretching process, increasing the stretching force in stages to avoid stress concentration caused by excessive deformation in a single step, is also an effective method. For example, when processing spiral aluminum plate hyperbolic materials, multiple stretching passes combined with intermediate annealing can significantly reduce springback.
The precision of cutting and splicing directly affects the building's appearance. Laser cutting, due to its small heat-affected zone and smooth edges, is the preferred method for cutting aluminum plate hyperbolic materials; waterjet cutting is suitable for heat-sensitive aluminum materials, avoiding localized deformation caused by high temperatures. During splicing, TIG welding or riveting processes must be used to ensure joint strength and flatness. For large curved surfaces, 3D scanning technology is needed to detect splicing errors and adjust the plate positions promptly to prevent accumulated errors from affecting the overall shape.
During the on-site installation phase, digital technology is essential to ensure precision. Using a BIM model to generate installation coordinate points, coupled with a total station for precise positioning, ensures a perfect fit between each aluminum plate hyperbolic structure and the keel system. For irregularly shaped structures, adjustable supports are used, with fine-tuning bolts compensating for processing or installation errors. After installation, surface smoothness testing is required. Laser inspection equipment scans the overall shape, generating deviation cloud maps to guide subsequent corrections.
From material selection to installation and acceptance, the high-precision molding and stress control of aluminum plate hyperbolic structures is a systematic engineering process. The application of high-strength aluminum alloys provides the material foundation for complex shapes, digital technology is integrated throughout the design, processing, and installation processes, and stress control processes ensure the long-term stability of the structure. With the widespread adoption of technologies such as five-axis machining and intelligent welding, the manufacturing precision and efficiency of aluminum plate hyperbolic structures continue to improve, providing broader creative possibilities for architectural curved surface design.
