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

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Abstract

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.

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Abbreviations

σ, ɛ :

Stress and strain

K :

Material strength coefficient

E :

Elastic modulus

n :

Strain hardening exponent

r :

Normal anisotropic coefficient

ν :

Poisson’s ratio

R :

Die radius

h :

Flange height

t :

The thickness of blank

ρ :

Neutral radius

θ :

Bend angle

S W :

The surface of web

\(S_{i}^{CA}\) :

The arc surface

\(S_{i}^{CF}\) :

The flange surface

\(F_{ik}^{NW}\) :

The normal planes

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Acknowledgements

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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Authors and Affiliations

  1. Key Lab of Fundamental Science for National Defense of Aeronautical Digital Manufacturing Process, Shenyang Aerospace University, Shenyang, 110136, China

    Ling-Yun Zhang, Shuai Zhou & Tian-Zhang Zhao

  2. Chengdu Aircraft Industrial (Group) Co., Ltd, Chengdu, 610092, China

    Yi-Pan Zeng

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  1. Ling-Yun Zhang
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  2. Shuai Zhou
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Correspondence to Shuai Zhou.

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Zhang, LY., Zhou, S., Zhao, TZ. et al. An Intelligent Method to Design Die Profile for Rubber Forming of Complex Curved Flange Part. Int. J. Precis. Eng. Manuf. 20, 111–119 (2019). https://doi.org/10.1007/s12541-019-00049-5

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