Abstract
Flexible forming with rubber pad is a forming technique that is commonly used in the aeronautic and automotive industries to produce parts with complex shapes from thin sheet metal. The purpose of this chapter is to compare between using flexible punch or flexible die in sheet metal forming with rubber pad. A finite element simulation is carried out to predict the behavior of the flexible stamping process of aluminum sheet metal with the two techniques of forming. For the sheet metal, an elastoplastic constitutive model is adopted and implemented in ABAQUS/Standard software via UMAT subroutine. However, a Mooney–Rivlin hyperelastic model is adopted for the rubber pad. Results predicted numerically consist of comparing the variation of some key parameters process using two deformation styles in order to produce safety parts without localized severe deformation. It was found that using rubber as flexible die may reduce the thinning rate and values of equivalent plastic strain in the formed part. Also, based on the Forming Limit Diagram (FLD) analysis, using flexible die instead of flexible punch may successfully form part without necking and micro crack and without localized severe deformation that can lead to fracture.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Belhassen L, Koubaa S, Wali M, Dammak F (2016) Numerical prediction of springback and ductile damage in rubber-pad forming process of aluminum sheet metal. Int J Mech Sci 117:218–226
Ben Said L, Mars J, Wali M, Dammak F (2016) Effects of the tool path strategies on incremental sheet metal forming process. Mech Ind 17(4):411
Browne DJ, Battikha E (1995) Optimisation of aluminium sheet forming using a flexible die. J Mater Process Technol 55:218–223
Dirikolu MH, Akdemir E (2004) Computer aided modelling of flexible forming process. J Mater Process Technol 148:376–381
Lee JW, Kwon HC, Rhee MH, Im YT (2003) Determination of forming limit of a structural aluminum tube in rubber pad bending. J Mater Process Technol 140:487–493
Liu Y, Hua L, Lan J, Wei X (2010) Studies of the deformation styles of the rubber-pad forming process used for manufacturing metallic bipolar plates. J Power Sources 195:8177–8184
Koubaa S, Mars J, Wali M, Dammak F (2017) Numerical study of anisotropic behavior of Aluminum alloy subjected to dynamic perforation. Int J Impact Eng 101:105–114
Mars J, Wali M, Jarraya A, Dammak F, Dhiab A (2015) Finite element implementation of an orthotropic plasticity model for sheet metal in low velocity impact simulations. Thin-Walled Struct 89:93–100
Peng L, Hu P, Lai X, Mei D, Ni J (2009) Investigation of micro/meso sheet soft punch stamping process-simulation and experiments. Mater Des 30:783–790
Ramezani M, Ripin ZM, Ahmad R (2009) Computer aided modelling of friction in rubber-pad forming process. J Mater Process Technol 209:4925–4934
Ramezani M, Ripin ZM, Ahmad R (2010) Sheet metal forming with the aid of flexible punch, numerical approach and experimental validation. CIRP J Manuf Sci Technol 3:196–203
Sala GA (2001) Numerical and experimental approach to optimize sheet stamping technologies: (Part II)—aluminium alloys rubber-forming. Mater Des 22(4):299–315
Thiruvarudchelvan S (1993) Elastomers in metal forming: a review. J Mater Process Technol 39:55–82
Wali M, Autay R, Mars J, Dammak F (2016) A simple integration algorithm for a non-associated anisotropic plasticity model for sheet metal forming. Int J Numer Meth Eng 107(3):183–204
Wali M, Chouchene H, Ben Said L, Dammak F (2015) One-equation integration algorithm of a generalized quadratic yield function with Chaboche non-linear isotropic/kinematic hardening. Int J Mech Sci 92:223–232
Watari H, Ona H, Yoshida Y (2003) Flexible punching method using an elastic tool instead of a metal punch. J Mater Process Technol 137:151–155
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2018 Springer International Publishing AG
About this paper
Cite this paper
Belhassen, L., Ben Said, L., Koubaa, S., Wali, M. (2018). Effects of Using Flexible Die Instead of Flexible Punch in Rubber Pad Forming Process. In: Haddar, M., Chaari, F., Benamara, A., Chouchane, M., Karra, C., Aifaoui, N. (eds) Design and Modeling of Mechanical Systems—III. CMSM 2017. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-319-66697-6_26
Download citation
DOI: https://doi.org/10.1007/978-3-319-66697-6_26
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-66696-9
Online ISBN: 978-3-319-66697-6
eBook Packages: EngineeringEngineering (R0)