Computer-aided modeling of the rubber-pad forming process

The conventional way to develop press-formed metallic components requires a burdensome trial-and-error process for setting-up the technology, whose success depends largely on the operator's skill and experience. The finite element (FE) simulations of a sheet-metal-forming process help a manufacturing engineer to design a forming process by shifting the costly press-shop try-outs to the computer-aided design environment. Numerical simulations of a manufacturing process, such as rubber-pad forming, have been introduced in order to avoid the trial-and-error procedure and shorten the development phases when tight times-to-market are demanded. The main aim of the investigation presented in this paper was to develop a numerical model that would be able to successfully simulate a rubber-pad forming process. The finite-element method was used for blank- and rubber-behavior predictions during the process. The study was concerned with a simulation and investigation of significant parameters (such as forming force and stress, and strain distribution in a blank) associated with the rubber-pad forming process and the capabilities of this process regarding the manufacturing of aircraft wing ribs. The simulation and investigation carried out identified the stress and strain distribution in a blank as well as the forming force. Experimental analyses of a rib with a lightening hole showed a good correlation between FE simulations and experimental results