Development Of Finite Element Modeling Module And Research On Process Parameters Of Rubber Forming

Rubber forming is one of the most important methods of sheet metal parts forming in aviation enterprises.Nowadays,with the improvement of precision of aircraft sheet metal parts manufacturing and the development of computer technology,it is a trend to study rubber forming process of sheet metal parts by using numerical simulation technology.However,operators are not only required to be familiar with the FEA softwares,but also to master certain finite element theory and professional knowledge.In the meantime,the process of building a finite element model is complicated and has low efficiency.Therefore,some research was made.Combined with the process of rubber forming FEM(finite element modeling),a FEM module for rubber forming based on ANSYS Workbench was developed by Java Script and ANSYS Workbench software development kit.The developed module includes: the menu used to generate the analysis process and the material library in the Project interface;parametric modeling template for rubber forming which is based on Design Modeler;and FEM template for rubber forming which is based on Design Simulation.With the help of the developed module,a finite element model can be created rapidly and accurately.The rubber forming process of typical sheet metal parts was analyzed,the simulation results agreed well with the results of experiment,which proved that the developed module was effective.By applying the developed module,the rubber forming process of typical parts were simulated and the influence of process parameters were further studied,the results show that: some gentle wrinkles can be eliminated and the springback can be reduced by increasing the forming pressure;with the increasing of the forming pressure,the thickness of the shrink flanging area tends to increase and the thickness at the transition corner of joggle decreases.By using the side blank holder,the forming process of the shrink flanging parts with large curvature was studied,and the influence of the main geometric parameters on the forming parts was analyzed.The rubber forming process of the typical parts was simulated with and without side blank holder.The results proved that the side blank holder increases the tensile stress,reduces the compression stress and avoids the wrinkles in the forming process,and it also solves the wrinkling problem which cannot be eliminated only by increasing the forming pressure.