An Intelligent Method to Design Die Profile for Rubber Forming of Complex Curved Flange Part

  • Ling-Yun Zhang
  • Shuai ZhouEmail author
  • Tian-Zhang Zhao
  • Yi-Pan Zeng
Regular Paper


Rubber forming is an important forming process for the manufacture of aircraft sheet metal parts. The springback is one of the main defects in rubber forming. Classical springback compensation by displacement adjustment method using finite simulation is not satisfactory. In this research, the algorithms of compensating the arc and flange surface of complex curved flange with correction formula are proposed by experiment. The correction formula was developed based on the CATIA V5 R19 using Component Application Architecture. Compensate profile is presented including surface pick up, line pick up, division, compensation, extending, and trimming. The die profile of part with complex curved flanges in aircraft could be designed rapidly. It was found that the forming pressure has a little effect on the springback. This is within the tolerance limits of the part. The results reveal the method can achieve the industrial part precisely. The method is demonstrated on an aircraft wing rib part.


Rubber forming Complex curved flange part Forming die profile Springback compensation 

List of Symbols

σ, ɛ

Stress and strain


Material strength coefficient


Elastic modulus


Strain hardening exponent


Normal anisotropic coefficient


Poisson’s ratio


Die radius


Flange height


The thickness of blank


Neutral radius


Bend angle


The surface of web


The arc surface


The flange surface


The normal planes



The authors would like to thank Hafei Aviation Industry Co., Ltd during the work. The research is supported by the aviation enterprise cooperation project (No. XY201375).


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Copyright information

© Korean Society for Precision Engineering 2019

Authors and Affiliations

  • Ling-Yun Zhang
    • 1
  • Shuai Zhou
    • 1
    Email author
  • Tian-Zhang Zhao
    • 1
  • Yi-Pan Zeng
    • 2
  1. 1.Key Lab of Fundamental Science for National Defense of Aeronautical Digital Manufacturing ProcessShenyang Aerospace UniversityShenyangChina
  2. 2.Chengdu Aircraft Industrial (Group) Co., LtdChengduChina

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