Abstract
In many manufacturing fields such as the aeroplanes and automobiles industries, the control of the thinning variations in produced parts is a major point to investigate since good thickness distribution mean the reliability of these products. In this framework, several experimental and numerical modeling tests have been developed for the purpose of studying phenomenon of thinning during rubber pad forming process. The low carbon steel (AISI 1080) has been used as the blank material. Three forming block shapes had been used (flat, hemispherical and complex), rubber pad with three different hardness (50, 60 and 70 Shore A) also the rubber pad thickness have (40, 60 and 80 mm). The results have showed that improvement in thickness distribution occurred with decrease in rubber hardness and thickness distribution is various from one deformation style to other.
Highlights
In sheet metal forming operations, the geometry of blank sheet follows the geometry of die cavity
The flexible die forming is employed to acquire uniform forming pressure distribution on all formed workpiece sides as it is formed to geometry of forming block [2,3],the uniform forming of sheet leads to perform good thickness distribution thereby overcoming thinning which occurs in conventional sheet metal forming [4,5]
The results revealed that the rubber pad forming is very applicable for forming parts without excessive thinning
Summary
In sheet metal forming operations, the geometry of blank sheet follows the geometry of die cavity. The results obvious that the forming force is inversely proportional to sheet for same forming travel It has found for increasing the thickness of pad improved the necessary forming energy. The effect of sheet thickness and type on the rubber pad forming operation introduced in the research of Niknejd and Karami [8] their discoveries offered that the radius of bending for the produced parts increase when width cavity of forming block improved, so the forming force decreases. The hardness of rubber becomes prominent effect in performing the required product shape, Tandogan and Eyercioglu [10] have studied the effect of Polyurethane hardness on forming of dome shaped parts, Polyurethane materials with 60 and 80 shore A, Aluminum sheet (Al 1100) with 0.5 mm thickness has used as blank material in experimental work and numerical modeling.
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