| The high flexible bending of profile with hyper-elastic pad is a novel technique, especially suitable for small lot or single part production of stiff and lightweight alloy with complicated section. The obtained parts with highly complexity of the shape as well as higher accuracy enable the rubber pad bending to be a promising method for structure lightweight design in aerospace and automotive industries.In this paper, based on the principle of the rubber pad bending and the process characteristic, the numerical control device for rubber pad bending was designed and manufactured. The advantages of this device are simple structure, flexible operation, high efficiency and high precision. To characterize material behavior of the rubber pad and profile for FE analysis, the material properties of the profile and rubber pad were measured by the tensile and compression test.Accurate FE model was built to simulate the rubber pad bending process by using finite element analysis software ABAQUS. FE analysis was carried out to investigate the effect to curvature radius of main process parameters such as the material property of rubber pad, roller stroke, roller diameter and bending layouts. Curvature radius is decrease gradually with the roller stroke increase. The experimental and numerical results appear to be in excellent agreement.The deformation mechanism of the rubber pad bending was researched by the Visualization module of the ABAQUS. The law of the curvature radius in the rubber pad bending process is analyzed, and through the force analysis of the different stages of the overall bending process to reveals the deformation mechanism of the rubber pad bending. The rule of process parameters influence on the curvature radius is verified by the effect to the deformation degree of these parameters. Roller stroke, thickness of rubber pad and bending layouts has important influence on curvature radius, while roller diameter has lower influence. |
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