Numerical And Experimental Analysis Of The Process Of Aviation Drawpiece Forming Using Rigid And Rubber Punch With Various Properties

Abstract

Abstract This paper presents the results of the numerical analysis and experimental research of the forming process of aviation drawpiece made from 0.6 mm thick Inconel 625 sheet metal. First phase of testing was conducted using rigid steel tools for drawpiece forming. Results of conducted simulations show that during rigid tool forming, the middle of the drawpiece losses stability. In consequence, rigid tool forming leads to the formation of unacceptable wrinkles on the drawpiece. Subsequent experimental research confirmed wrinkles of the metal drawpiece in this area. It was assumed that in order to eliminate this negative phenomenon, minor changes in technology and tool construction would have to be made. The drawpiece will be shaped by means of a flexible tool, than re-shaped using rigid tools. In the second phase of the research, tooling design changes have been made. They consisted of replacing the steel punch with a specially designed stamp susceptible for deformation. FEM numerical simulations were performed for flexible punch forming made of polyurethane elastomer with different hardness (50, 70, 85 and 90 Sh A). On their basis, the effect on the mechanical characteristics of the elastomeric drawing process and the formation of wrinkles was shown. They can be effectively eliminated by the use of a punch with hardness of 90 Sh A, which has also been confirmed by experimental research. In addition, the paper presents a comparative analysis of the deformations in selected actual drawpiece areas and in the elastomeric punch with hardness 90 Sh A computer model. The actual drawpiece deformation schedule and the values were determined using photogrammetric system Argus v.6.3., while the computer modeled drawpiece was based on FEM calculations performed in the MARC / Mentat system. In conclusion the difficulties as well as the advantages and disadvantages in determining the deformation of sheet metal parts were indicated using photogrammetric system Argus and FEM.