Rubber-pad forming processes: Technology and applications

418 Pages·2012·23.77 MB·English

by  Maziar Ramezani, Zaidi Mohd Ripin

Rubber-pad forming processes
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Rubber-pad forming
processes
Technology and
applications
M R
AZIAR AMEZANI

AND
Z M. R
AIDI IPIN
Published by Woodhead Publishing Limited,
80 High Street, Sawston, Cambridge CB22 3HJ, UK
www.woodheadpublishing.com
Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102–3406, USA
Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road,
Daryaganj, New Delhi – 110002, India
www.woodheadpublishingindia.com
First published 2012, Woodhead Publishing Limited
© M. Ramezani and Z. Ripin, 2012
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources.
Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts
have been made to publish reliable data and information, but the authors and the publisher
cannot assume responsibility for the validity of all materials. Neither the authors nor the
publisher, nor anyone else associated with this publication, shall be liable for any loss,
damage or liability directly or indirectly caused or alleged to be caused by this book.
Neither this book nor any part may be reproduced or transmitted in any form or by any
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The consent of Woodhead Publishing Limited does not extend to copying for general
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Trademark notice: Product or corporate names may be trademarks or registered trademarks,
and are used only for identifi cation and explanation, without intent to infringe.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Control Number: 2011942365
Woodhead Publishing ISBN: 978-0-85709-094-2 (print)
ISBN: 978-0-85709-549-7 (online)
Typeset by Refi neCatch Limited, Bungay, Suffolk
Printed in the UK and USA.
Contents
List of fi gures and table ix
Preface xxi
About the authors xxiii
1 Introduction to sheet metal forming processes 1
1.1 Introduction 1
1.2 Sheet metal forming processes 2
1.3 Flexible-die forming 5
1.4 Bibliography 21
2 Principles of rubber-pad forming 23
2.1 Introduction 23
2.2 Advantages and disadvantages of
rubber-pad forming process 24
2.3 Guerin process 26
2.4 Verson-Wheelon process 30
2.5 Marform process 32
2.6 Verson hydroform process 34
2.7 SAAB rubber-diaphragm process 36
2.8 Maslennikov’s process 37
2.9 Tube bulging 39
2.10 Demarest process 41
2.11 Bibliography 42
3 Characteristics of elastomer materials 43
3.1 Introduction 43
3.2 Elastomer types 46
v
Rubber-pad forming processes
3.3 Compounding 47
3.4 Typical elastomers used in rubber-pad forming
processes 48
3.5 Mechanical properties of elastomers – linear
elastic 54
3.6 Mechanical properties of elastomers – non-
linear elastic 58
3.7 Hyperelastic models and elastomer mechanics 59
3.8 Bibliography 64
4 Forming of shallow parts using rubber tools 65
4.1 Introduction 65
4.2 Guerin process 67
4.3 Free forming 77
4.4 Bending 83
4.5 Multi-point forming of sheet metals
with rubber cushions 97
4.6 Bibliography 100
5 Piercing of sheet metals using rubber punch 103
5.1 Introduction 103
5.2 Analysis of fracture load 107
5.3 Analysis of ram movement 113
5.4 Quality of the pierced specimen 116
5.5 Bibliogaphy 117
6 Deep drawing of sheet metals using
friction-actuated blank-holding technique 119
6.1 Introduction 119
6.2 Theoretical investigation of conventional
deep drawing of a cylindrical cup from a
circular disk 121
6.3 Friction-actuated blank-holding technique 126
6.4 Bibliography 147
vi
Contents
7 Deep drawing using Verson hydroforming process 149
7.1 Introduction 149
7.2 Theoretical analysis of drawing stress 153
7.3 Analysis of process parameters 158
7.4 Deep drawing with elastomer membrane 168
7.5 Bibliography 171
8 Deep drawing of sheet metals by Marform
technique 173
8.1 Introduction 173
8.2 Theoretical analysis of Marform process 175
8.3 Pressure distribution at different portions
of rubber die 180
8.4 Results of analytical approach 181
8.5 Development of thickness strain 186
8.6 Forming limit diagram 191
8.7 Bibliography 194
9 Deep drawing of sheet metals by Maslennikov’s
technique 195
9.1 Introduction 195
9.2 Theoretical analysis 199
9.3 Analysis of fi rst stage drawing 211
9.4 Analysis of repeated drawing operations 216
9.5 Collar drawing 219
9.6 Redrawing with a rubber ring 223
9.7 Bibliography 226
10 Tube bulging using rubber rods 229
10.1 Introduction 229
10.2 Tube end bulging 232
10.3 Bulging at the middle of tube 237
10.4 T-branch forming 242
10.5 Theory of axisymmetric tube bulge forming 246
vii
Rubber-pad forming processes
10.6 Other tube bulging processes 249
10.7 Bibliography 255
11 Conclusions 257
Combined bibliography 261
Index 273
viii
List of fi gures and table
Figures
1.1 Bulge forming of tubes using hydroforming
process 9
1.2 Sheet hydroforming process 9
1.3 Hydro-formed bellows using a circular insert
ring with axial feeding 11
1.4 Hydro-formed tube double sheet component 12
1.5 Hot metal gas forming process 14
1.6 Magnesium alloy tube after hot metal gas
forming 14
1.7 Viscous pressure forming process 17
1.8 Corrugated surface shape of a nickel-based
superalloy specimen formed by viscous
pressure forming process 19
1.9 Different rubber-pad forming operations 20
2.1 Tooling for the Guerin process 26
2.2 Auxiliary tools for rubber-pad forming
process 29
2.3 U-bending of sheet metals using rubber-pad
forming process 30
2.4 Verson-Wheelon process 31
2.5 Marform deep drawing process 32
2.6 Verson hydroforming process 36
2.7 SAAB rubber diaphragm forming 37
2.8 Maslennikov’s deep drawing process 38
2.9 Bulging T joints with rubber rod 39
ix