FEM Simulation as a Tool for Planning and Optimizing the Rubber Pad Forming Process

Abstract

Manufacturing press-formed metallic components by conventional methods needs a burdensome trial-and-error process to set up the technology, which success depends, largely, upon the operator’s skill and experience. The finite element (FE) simulations of sheet-metal-forming processes assist the manufacturing engineer to design a forming process by shifting the costly press-shop try-outs to the computer-aided design environment. The purpose of applying numerical simulations of a manufacturing process such as rubber-pad forming is 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 focused on simulating and investigating significant parameters (such as forming force and stress and strain distribution in a blank) which are associated with the rubber-pad forming process, also the capabilities of this process regarding the manufacturing of aircraft wing ribs and ships. As a result, the stress and strain distribution in a blank as well as the forming force were identified. The experimental analysis of a rib with a lightning hole showed a close correlation between the FE simulations and the experimental results.