The bending of an aluminum structural frame with a rubber pad

In this study, research for process design in the bending of a structural f rame of AA6061-T6 with a rubber pad was conducted. In this process, the con ventional lower die made of metal is replaced with a polyurethane pad, resu lting in high flexibility during bending. Vulcanized polyurethane rubber wi th a shore A hardness of 60 was used for the pad. Experiments on a newly de veloped bending machine were carried out by controlling the stroke of the r oller and the horizontal movement of the roller pad lower die. From this, t he relation between the roller path and the geometry of the materials bent was obtained for the process design of producing a roof-rail part of a pass enger car, the experimental result being compared with the target profile. For more accurate process design, it is required to control the roller path interactively. Based on experience in developing the prototype bending mac hine, it is construed that a fully automated bending system with a rubber p ad to produce various light-weight components for automotive body frames ca n be successfully developed. (C) 2001 Elsevier Science B.V. All rights rese rved.