1. Formability of sheet metal formed using rubber pad die with lateral forming force mechanism.
- Author
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Huang, Hao-Lun and Kuo, Chun-Chih
- Subjects
- *
GREY relational analysis , *METAL formability , *SHEET metal , *MANUFACTURING defects , *LATERAL loads - Abstract
Rubber pad forming is one of the primary ways of manufacturing aviation sheet metal components. In addition to reducing forming die costs, using elastic rubber in rubber pad forming prevents scratching on sheet metal, which is crucial for flight safety. However, during the forming process, the rubber pad primarily applies a vertical force to the sheet metal and cannot effectively exert pressure on the sheet metal laterally. Consequently, the contours of the finished product could fall outside specifications. This can cause severe manufacturing defects such as wrinkling or springback and therefore require a significant amount of labor to remedy and prevent any defects. As such, improvements in production efficiency are necessary. This study presents a rubber pad forming die with a lateral forming force mechanism that provides a lateral compressive stroke to the forming process of sheet metal via wedge-shaped structures; in other words, a lateral forming force to rubber pad forming is applied. In our exploration of stacking rubber pads of varying hardnesses in different orders, the maximum force was a larger-the-better objective, and the thickness compression ratio of the rubber pad was a smaller-the-better objective. We then combined grey relational analysis and the entropy method to identify the rubber pad stacking order and thicknesses with the optimal forming results. Subsequently, we constructed an actual rubber pad forming die with a lateral forming force mechanism as well as performed experiments and verification using 6061-T6 sheet metal with a thickness of 1 mm for aircraft wing reinforcement. The results demonstrated that employing rubber pad forming with a lateral forming force mechanism could reduce the amount of springback and surface wrinkling, meet blueprint requirements, and provide a new method and application of rubber pad forming for aviation sheet metal. [ABSTRACT FROM AUTHOR]
- Published
- 2025
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