Numerical simulation as a tool for optimizing tool geometry for rubber pad forming process

Muamar Benisa,Bojan Babic,Aleksandar Grbovic,Zoran Stefanovic

doi:10.5937/fmet1401067b

Abstract

To produce a new component there are a trial and error stage to obtain a part without defects, which strongly depends on operator's experience. At this stage, the experience of designer and manufacturers should give an important aid to reduce trials to realize the minimization of response time and cost with maximization of the product equality. Rubber pad forming highly improves the formability of the blank because the contact surfaces between the rigid die and the rubber pad is flexible. This method enables to produce sheet metal components with complex contour by relatively low cost because only one rigid die is required. However, in aerospace field, parts are produced in small sheet metal bending and small number of components. It means that it is not worthy for large investments in tools and process design. For these reasons, it is necessary to use FE simulation of manufacturing process during the conceptual design.

Highlights

There are other alternatives to form complex shape besides conventional forming processes such as deep drawing, bending, stretching, stamping and blanking
In order to reduce the processing time and to improve the precision of calculations which lead to the right design of tool dimensions, 2D axisymmetric FE models were created for different die dimensions Figure 2 (a) illustrates the geometrical model of the rib with lightening hole and Geometry parameters varied in FE simulations of rubber pad forming (Figure 2 (b))
Some parameters have higher influence on the value of plastic strain during the rubber pad forming process, and here tool geometry parameters (RI, RII, RIII and H shown in Figure 2(b)) have been studied

Summary

Introduction

There are other alternatives to form complex shape besides conventional forming processes such as deep drawing, bending, stretching, stamping and blanking. In order to reduce the processing time and to improve the precision of calculations which lead to the right design of tool dimensions, 2D axisymmetric FE models were created for different die dimensions (parameters) Figure 2 (a) illustrates the geometrical model of the rib with lightening hole and Geometry parameters varied in FE simulations of rubber pad forming (Figure 2 (b)) .

Results

Conclusion