Computer Aided Modelling of Rubber Pad Forming Process

2011 ◽  
Vol 473 ◽  
pp. 637-644 ◽  
Author(s):  
Antonio del Prete ◽  
Gabriele Papadia ◽  
Barbara Manisi
Keyword(s):  
Sheet Metal ◽  
Process Model ◽  
Process Analysis ◽  
Low Cost ◽  
Critical Parameters ◽  
Forming Process ◽  
Small Series ◽  
Rubber Pad Forming ◽  
Rubber Forming ◽  
Rigid Die

Rubber pad forming (RPF) is a novel method for sheet metal forming that has been increasingly used for: automotive, energy, electronic and aeronautic applications [1]. Compared with the conventional forming processes, this method only requires one rigid die, according to the shape of the part, and the other tool is replaced by a rubber pad [1]. This method can greatly improve the formability of the blank because the contact surface between the rigid die and the rubber pad is flexible. By this way the rubber pad forming enables the production of sheet metal parts with complex contours and bends. Furthermore, the rubber pad forming process is characterized by a low cost of the die because only one rigid die is required [2]. The conventional way to develop rubber pad forming processes of metallic components requires a burdensome trial-and-error process for setting-up the technology, whose success chiefly depends on operator’s skill and experience [4][5]. In the aeronautical field, where the parts are produced in small series, a too lengthy and costly development phase cannot be accepted. Moreover, the small number of components does not justify large investments in tooling. For these reasons, it is necessary that, during the conceptual design, possible technological troubles are preliminarily faced by means of numerical simulation [4],[6]. In this study, the rubber forming process of an aluminum alloy aeronautic component has been explored with numerical simulations and the significant parameters associated with this process have been investigated. Several effects, depending on: stamping strategy, component geometry and rubber pad characterization have been taken into account. The process analysis has been carried out thanks to an extensive use of a commercially finite element (FE) package useful for an appropriate set-up of the process model [7],[8]. These investigations have shown the effectiveness of simulations in process design and highlighted the critical parameters which require necessary adjustments before physical tests.

scholarly journals 3D printed prototyping tools for flexible sheet metal drawing

2021 ◽  
Author(s):  
Peter Frohn-Sörensen ◽  
Michael Geueke ◽  
Tadele Belay Tuli ◽  
Christopher Kuhnhen ◽  
Martin Manns ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Processing Parameters ◽  
Polymer Materials ◽  
Compression Tests ◽  
Forming Process ◽  
Resource Saving ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Small Series ◽  
Rubber Pad Forming

AbstractDue to the change from mass production to mass personalized production and the resulting intrinsic product flexibility, the automotive industry, among others, is looking for cost-efficient and resource-saving production methods to combining global just-in-time production. In addition to geometric manufacturing flexibility, additive manufacturing offers a resource-saving application for rapid prototyping and small series in predevelopment. In this study, the FDM process is utilized to manufacture the tooling to draw a small series of sheet metal parts in combination with the rubber pad forming process. Therefore, a variety of common AM polymer materials (PETG, PLA, and ABS) is compared in compression tests, from which PLA is selected to be applied as sheet metal forming die. For the rubber pad forming process, relevant processing parameters, i.e., press force and rubber cushion hardness, are studied with respect to forming depth. The product batch is examined by optical evaluation using a metrological system. The scans of the tool and sheet metal parts confirm the mechanical integrity of the additively manufactured die from polymer and thus the suitability of this approach for small series in sheet metal drawing processes, e.g., for automotive applications.

scholarly journals 3D printed prototyping tools for flexible sheet metal drawing

2020 ◽  
Author(s):  
Peter Frohn-Sörensen ◽  
Michael Geueke ◽  
Tadele Belay Tuli ◽  
Christopher Kuhnhen ◽  
Martin Manns ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Processing Parameters ◽  
Polymer Materials ◽  
Compression Tests ◽  
Forming Process ◽  
Resource Saving ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Small Series ◽  
Rubber Pad Forming

Due to the change from mass production to mass personalized production and the resulting intrinsic product flexibility, the automotive industry, among others, is looking for cost-efficient and resource-saving production methods to combining global just-in-time production. In addition to geometric manufacturing flexibility, additive manufacturing offers a resource-saving application for rapid prototyping and small series in pre-development. In this study, the FDM process was utilized to manufacture the tooling to draw a small series of sheet metal parts in combination with the rubber pad forming process. Therefore, a variety of common AM polymer materials (PETG, PLA and ABS) is compared in compression tests, from which PLA is selected to be applied as sheet metal forming die. For the rubber pad forming process, relevant processing parameters, i.e. press force and rubber cushion hardness, are studied with respect to forming depth. The product batch was examined by an optical evaluation using a metrological system. The scans of the tool and sheet metal parts confirm the mechanical integrity of the additively manufactured die from polymer and thus the suitability of this approach for small series in sheet metal drawing processes, e.g. for automotive applications.

Simulation and experiment researches on rubber pad forming of two-step channels by different dies

2021 ◽  
pp. 095440622110342
Author(s):  
Teng Fei ◽  
Wang Hongyu ◽  
Wang Guodong ◽  
Jiang Lei ◽  
Sun Juncai ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Design Strategy ◽  
Forming Process ◽  
Processing Technologies ◽  
Physical Experiments ◽  
Micro Channels ◽  
Rubber Pad Forming ◽  
Simulation And Experiment

Rubber pad forming is one of advance processing technologies. With both rubber pad and die, the sheet metal is stamped into the required shapes. The shapes of the die directly affect the final shapes of the channels on the sheet. With the developments of micro-channels, a new kind of two-step channels is concerned gradually in many fields. Since there are waved structures in these channels, many beneficial functions are caused. However, the manufacturing of this new kind channels by rubber pad forming are still not meticulously researched. This article is focused on the rubber pad forming process of different two-step channels. Different two-step channels are designed and made. Based on both FEM and physical experiments, the forming processes of these new channels are researched. The forming results are discussed and compared with each other, the best design strategy is also proposed through results.

scholarly journals Numerical and experimental studies on wrinkling control methods of sheet metal part with high curvature and large flange in rubber forming

2019 ◽  
Vol 11 (10) ◽  
pp. 168781401988378
Author(s):  
Lei Chen ◽  
Ying Bai ◽  
Zhengyi Jiang ◽  
Huiqin Chen ◽  
Can Wu ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Failure Modes ◽  
Optimal Parameter ◽  
Experimental Studies ◽  
Element Model ◽  
Resistance Force ◽  
Forming Process ◽  
Complex Deformation ◽  
Metal Forming Process ◽  
Rubber Forming

Wrinkling is one of the main failure modes in sheet metal forming process and may lead to assembly problems of the parts. Control of wrinkling is difficult due to the complex deformation behavior of the sheet metal. A finite element model for side blankholder method to control wrinkling was established and used for the simulation. Trials and simulations were conducted to analyze the parameters of wrinkling characteristics. Results show that with the increase in the angle of the side blankholder, the resistance force of the side blankholder decreases. The blank length on the side blankholder should be small enough. The fillet radius of the side blankholder should be large enough to reduce the deformation. The bottom gap between the die and the side blankholder cannot be too large because the support of the blank will decrease in the forming process. In order to verify the simulation results, three blank lengths (20, 15, and 5 mm) over the side blankholder were used in the experiment. The results of the comparison tests testify the reliability of the simulation. The optimal parameter of the blank length is 5 mm. A new clamp method was designed for wrinkling control to overcome the shortcomings of the side blankholder method. The precision of the part met the requirement using soft rubber and two layers of rubber plates.

Multi-Input Multi-Output (MIMO) Modeling and Control for Stamping

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Yongseob Lim ◽  
Ravinder Venugopal ◽  
A. Galip Ulsoy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Flow ◽  
Process Model ◽  
Complex Geometry ◽  
Flow Characteristics ◽  
Forming Process ◽  
Punch Force ◽  
Force System

The binder force in sheet metal forming controls the material flow into the die cavity. Maintaining precise material flow characteristics is crucial for producing a high-quality stamped part. Process control can be used to adjust the binder force based on tracking of a reference punch force trajectory to improve part quality and consistency. The purpose of this paper is to present a systematic approach to the design and implementation of a suitable multi-input multi-output (MIMO) process controller. An appropriate process model structure for the purpose of controller design for the sheet metal forming process is presented and the parameter estimation for this model is accomplished using system identification methods. This paper is based on original experiments performed with a new variable blank holder force (or variable binder force) system that includes 12 hydraulic actuators to control the binder force. Experimental results from a complex-geometry part show that the MIMO process controller designed through simulation is effective.

A Two-Pronged Approach for the Assessment of Springback Variability for Sheet Metal Forming Applications

2013 ◽  
Vol 554-557 ◽  
pp. 957-965 ◽  
Author(s):  
Jérémy Lebon ◽  
Guénhaël Le Quilliec ◽  
Rajan Filomeno Coelho ◽  
Piotr Breitkopf ◽  
Pierre Villon
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Numerical Models ◽  
Low Cost ◽  
Forming Process ◽  
Metal Forming Process ◽  
Small Random Perturbations ◽  
Complex Phenomena ◽  
Bending Under Tension

Springback assessment for sheet metal forming processes is a challenging issue which requires to take into account complex phenomena (physical non linearities and uncertainties). We highlight that the stochastic analysis of metal forming process requires both a high precision and low cost numerical models and propose a two-pronged methodology to address these challenges. The deep drawing simulation process is performed using an original low cost semi-analytical approach based on a bending under tension model with a good accuracy for small random perturbations of the physical and process parameters. The springback variability analysis is performed using an efficient stochastic metamodel, namely a sparse version of the polynomial chaos expansion.

A New Incremental Sheet Forming Process Based on a Flexible Supporting Die System

2007 ◽  
Vol 344 ◽  
pp. 607-614 ◽  
Author(s):  
E. Maidagan ◽  
Joachim Zettler ◽  
Markus Bambach ◽  
P.P. Rodríguez ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Additional Advantage ◽  
Stage Of Development ◽  
Industrial Sectors ◽  
Small Series ◽  
Incremental Sheet Metal Forming ◽  
Flexible Die

Nowadays many industrial sectors use forming processes in order to produce sheet metal components. The most widely used processes are stamping and deep drawing, which are based on big, costly dies and presses. These processes require large initial investment and specific dies for each part, which makes them inflexible and only profitable for large batches. A possible approach to small series production is based on the incremental sheet forming technique (ISF), which consists of a gradual plastic deformation of flat sheet metal by the action of a CNC controlled tool. Equipment such as a 3-axis milling machine can be used for ISF, such that the initial investment costs in ISF are around 5-10% of those required to set up a production line for conventional stamping. In its current stage of development, dedicated dies are often used as support tools in ISF. However, due to the fact that the forming forces are low in ISF, the dies can be made out of cheap materials like resin or wood. Although this is an additional advantage over stamping, the need to use additional tools still reduces the flexibility of the process. The present paper details the concept of a truly “dieless” incremental forming process. In the framework of the SCULPTOR EU project, the authors are working on an innovative concept of incremental sheet metal forming which is based on the replacement of the commonly used dies by a second forming tool which moves in a coordinated way with the first forming tool, thus creating a flexible die system, which does not depend on the specific geometry of the part to be formed. The present work summarizes the results obtained up to now in two fields: (i) the development of a prototype for the flexible die system to be included both in milling machines or combined with robots and (ii) process modelling to improve the understanding of the process.

Formability Prediction for Thermal Stamping of Magnesium Alloy Sheet Based on M-K Model

2013 ◽  
Author(s):  
Z. H. Chen ◽  
Y. Wen ◽  
C. H. Sun
Keyword(s):  
Magnesium Alloy ◽  
Sheet Metal ◽  
Low Cost ◽  
Alloy Sheet ◽  
Forming Limit ◽  
Forming Process ◽  
Element Analysis ◽  
High Productivity ◽  
Magnesium Alloy Sheet ◽  
Formability Prediction

Sheet metal stamping processes play an important role among the mechanical manufacturing operation, since they are characterized by high productivity and reliability at low cost, low material waste and almost net shapes from design. In this study, based on the Marciniak and Kuczynski (M-K) model and the forming limit diagrams (FLD), the formability prediction for thermal stamping of magnesium alloy sheet has been carried out by means of the commercial finite element analysis software ABAQUS. Moreover, related experiments of thermal stamping were also performed to validate the model. The comparison between the numerical result and experimental observation shows a good agreement. Therefore, it may indicate that the presented approach can be employed in formability prediction of thermal sheet metal forming process.

Numerical Simulation and Experiment of Aluminum Sheet Metal Springback in New Quenching State

2010 ◽  
Vol 97-101 ◽  
pp. 2567-2570
Author(s):  
Lei Chen
Keyword(s):  
Numerical Simulation ◽  
Tensile Strength ◽  
Numerical Method ◽  
Sheet Metal ◽  
Total Elongation ◽  
Forming Process ◽  
Tool Shape ◽  
Metal Rubber ◽  
Rubber Forming ◽  
Simulation And Experiment

2024-T3 aluminium sheet metal rubber forming process after quenching is studied. The tensile properties of 2024-T3 after quenching are measured. It is found that the yield strength and ultimate tensile strength are reduced, whilst total elongation value is increased. Springback character of rubber forming is studied by numerical method and springback compensation of rib flanging is studied. The simulation is compared with experiment. It is found that the tool shape considering springback is got using numerical method. The parts after springback achieve the design accuracy. So the method can be used in the application of rubber net forming.

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