The bending of an aluminum structural frame with a rubber pad

In this study, research for process design in the bending of a structural frame of AA6061-T6 with a rubber pad was conducted. In this process, the conventional lower die made of metal is replaced with a polyurethane pad, resulting in high flexibility during bending. Vulcanized polyurethane rubber with a shore A hardness of 60 was used for the pad. Experiments on a newly developed bending machine were carried out by controlling the stroke of the roller and the horizontal movement of the roller pad lower die. From this, the 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 passenger 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 machine, it is construed that a fully automated bending system with a rubber pad to produce various light-weight components for automotive body frames can be successfully developed.