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

摘要

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.