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

Zhang, Lingyun; Zhou, Shuai; Zhao, Tian-Zhang; Zeng, Yipan

doi:10.1007/s12541-019-00049-5

Cited by 8 publications

(5 citation statements)

References 14 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The process followed in the simulation to evaluate the component's anticipated final shape did not match the CMM procedure used to measure the manufactured panel's distortion. The original position alignment of the simulation mesh and the nominal surface was used throughout the investigation, and was the typical procedure seen in all the publications [2] [3] [8] - [14]. PAM-STAMP did allow for a best-fit alignment of the mesh and the component surface.…”

Section: Metrology and Simulation Results Comparisonmentioning

confidence: 99%

“…Much of the research investigating die sheet hydroforming and state-of-the-art simulation software packages are limited to simple, shaped components. The shapes are typically singe-edge flanged components rather than sizeable complex-shaped panel-type components [9] [10] [11] [12] [13] [14]. The die sheet hydroforming simulation process is aligned with flanged and tube components.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Die Sheet Hydroforming of a Complex-Shaped Aa2024-W Aircraft Skin Panel — From Concept to Final Component

Serfontein

Damm²,

Sacks

et al. 2021

SAJIE

View full text Add to dashboard Cite

Product design in the early stages requires a more quantitative process to ensure that the simulation study's outcome will meet expectations. The purpose of this study was to determine whether a manufacturing simulation software package could effectively evaluate and validate the conceptualised blank and tooling to manufacture a sizeable complexshaped aluminium alloy aircraft panel using die sheet hydroforming. Blank and tool concepts were conceptualised, evaluated, and validated digitally using the forming process conceptualisation cycle. Without the need to trial several blank and tool concepts physically, a significant saving was achieved using a resource-efficient development process. Even without modelling the hyperelastic rubber elements, a successful die sheet hydroformed simulation result was conducted. However, the study showed that a rubber-to-metal friction coefficient must be incorporated appropriately. The study further showed the lack of standard metrology methods in commercial simulation packages to evaluate a simulation result accurately. Simulation metrology is a new area of interest that requires further development. This research contributes to improving the sheet metal forming simulation process and, specifically, die sheet hydroforming process simulation. The study will benefit the aerospace and automotive industry and promote the adoption of digital manufacturing processes.

show abstract

Section: Metrology and Simulation Results Comparisonmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Die Sheet Hydroforming of a Complex-Shaped Aa2024-W Aircraft Skin Panel — From Concept to Final Component

Serfontein

Damm²,

Sacks

et al. 2021

SAJIE

View full text Add to dashboard Cite

show abstract

“…The Johnson-Cook failure model is a failure model like the J-C constitutive model, considering the effects of stress state, strain rate and temperature on material failure. The expression is as follows [21]:…”

Section: B: Johnson-cook Failure Modelmentioning

confidence: 99%

Study of the Vibration Mechanism and Process Optimization for Abrasive Belt Grinding for a Blisk-Blade

Liu

Xiao

et al. 2019

IEEE Access

View full text Add to dashboard Cite

The blisk is a key component of aero engines, and its surface processing quality directly affects the service performance of the aero engine. In using the new open belt grinding process, different degrees of vibration will occur, and they seriously affect the dimensional accuracy and surface quality of the blisk-blade profile. In view of the above-mentioned problems, this paper first built the physical model for the blisk-blade abrasive belt grinding and analyzed the weak stiffness characteristics of the blisk-blade abrasive belt grinding system. Then, based on the kinetic analysis method, the grinding mechanism of the abrasive belt of the blisk-blade was studied, and the process parameters and stability grinding conditions affecting the grinding stability of the blisk-blade belt were analyzed. In addition, the grinding process of the blisk-blade profile belt was simulated by a numerical method. The influence of different process parameters on the grinding vibration of the blisk-blade was quantified, and the optimal combination of process parameters was obtained. Finally, the feasibility of process parameter optimization was verified experimentally. Studies have shown that the weak stiffness of the blisk-blade grinding system always runs through the entire grinding process, but the impact size has a primary and secondary order. The grinding vibration of the blisk-blade belt is related to the process parameters, such as the grinding positive pressure, the belt speed, the feed rate, and the contact wheel hardness. The primary and secondary orders of each influencing factor are grinding positive pressure, belt speed, feed rate, and contact wheel hardness. The optimal combination of various factors was obtained: belt speed v b = 3 m/s, grinding positive pressure F n = 4 N, feed rate v g = 0.6 m/s, and contact wheel hardness Hs/A55. Through the sand belt grinding verification experiment on the blisk-blade, the grinding belt grinding quality of the blisk-blade surface roughness and blade profile precision is improved after the process optimization.

show abstract

“…Fan et al(2021) established the mapping model between springback angle and geometric parameters of the flange by the response surface method, presenting a novel method for springback prediction which incorporated k nearestneighbor within optimized grey relation analysis, verified by experiments. Zhang et al(2019) proposed the algorithms of compensating the arc and flange with correction formula by experiment, including surface and line pick up, division, compensation, extending, and trimming, where the results suggested that this method achieved an aircraft wing rib part precisely. predicted the degree of wrinkles in the sheet forming process by the comparison analysis of the titanium alloy material of the Fukui-Cone cup in simulation experiment, exploring how the hardness of the rubber influenced the wrinkle in the forming of the convex edge of the sheet, verified by experiments.…”

Section: Introductionmentioning

confidence: 99%

Research on wrinkling in rubber forming of the convex flange with 2A12 aluminum alloy sheet

Tao

XIAO

et al. 2023

JAMDSM

View full text Add to dashboard Cite

The orthogonal experiment was established to reduce the wrinkling of convex flange rubber forming with 2A12 aluminum alloy sheet. The impact factors consisted of the feed of master-cylinder, the hardness of the rubber, and the radius of the die. The rubber forming was simulated for the quantities, widths, and heights of the wrinkles in ABAQUS software, where the results was analyzed by gray correlation. Theoretically the greatest influence on the wrinkles is the feed of master-cylinder that the more the feed is, the smaller the wrinkles are. However, neither in the simulation nor in the experiment, all the wrinkles of the convex flanged parts still could not be flattened when the master-cylinder was fed to the rubber's compression limit. Aiming to further eliminate wrinkling, a new method called multi-stage rubber forming was proposed, in which four extra-cylinders were added to the broadside of the container to enhance the forming force. Both the numerical simulation and experiment were taken into the multi-stage rubber forming, proving that multi-stage rubber forming could effectively reduce the wrinkling in rubber forming of the convex flange, as the feed of the extra-cylinders increased risks of the wrinkles. When the feed of the extra-cylinders was set 8 mm while the master-cylinder 34 mm, the wrinkle of the convex curve bending edge could be eliminated smoothly.

show abstract

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

Cited by 8 publications

References 14 publications

Die Sheet Hydroforming of a Complex-Shaped Aa2024-W Aircraft Skin Panel — From Concept to Final Component

Die Sheet Hydroforming of a Complex-Shaped Aa2024-W Aircraft Skin Panel — From Concept to Final Component

Study of the Vibration Mechanism and Process Optimization for Abrasive Belt Grinding for a Blisk-Blade

Research on wrinkling in rubber forming of the convex flange with 2A12 aluminum alloy sheet

Contact Info

Product

Resources

About