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Rubber Rubber forming, also known as rubber pad forming or elastomeric forming, is a metal forming process that uses a rubber pad or diaphragm to shape
Forming sheet metal into desired contours or shapes. This process is often used for creating parts with shallow or gentle curves, and it offers advantages
such as flexibility, reduced tooling costs, and improved surface finishes. Rubber forming is commonly employed in industries like aerospace,
automotive, and art and design.
Here's an overview of the rubber forming process:
• Die Preparation: A flat sheet of metal is placed over a die that has the desired shape or contour. The die is often a male die, meaning it is a
positive replica of the final part shape.
• Rubber Pad Placement: A rubber pad or diaphragm is placed over the sheet metal. The rubber pad is typically made of a flexible and
elastomeric material, such as rubber or silicone.
• Forming: The rubber pad is pressurized, causing it to apply pressure evenly over the sheet metal. The applied pressure deforms the metal,
causing it to take on the shape of the die underneath the rubber pad. (Source of images:
• Deformation and Release: The rubber pad continues to apply pressure until the desired level of deformation is achieved. Once the forming https://www.mdpi.com/2075-
process is complete, the pressure is released, and the formed part is removed from the die. 4701/12/3/491)
Key characteristics of rubber forming include:
• The process is well-suited for parts with shallow or gradual curves, as opposed to sharp bends or deep draws.
• The rubber pad provides even pressure distribution, which can lead to improved surface finish and reduced wrinkling.
Advantages of rubber forming include:
• Low tooling costs compared to traditional die forming methods.
• Reduced risk of surface imperfections due to even pressure distribution.
• Flexibility to produce parts with varying contours without the need for complex dies.
Limitations of rubber forming include:
• The process may not be suitable for producing parts with deep or complex shapes.
• The rubber pad's durability and lifespan can be a consideration for high-volume production.
Rubber forming is used in various industries to create a range of components, such as aircraft panels, automotive body parts, decorative pieces,
and prototypes. It offers a cost-effective and flexible solution for producing parts with smooth, curved surfaces that require minimal tooling
investment.
Powder Powder metallurgy (PM) is a manufacturing process that involves the production of metal parts and components from finely powdered metals and
Metallurgy alloys. It offers several advantages, including the ability to produce complex shapes, control material properties, and minimize material waste.
The powder metallurgy process typically involves the following steps:
• Powder Production: Metal powders are produced through various methods, such as atomization (breaking up molten metal into fine droplets),
mechanical comminution (crushing and grinding), and chemical reduction. The powder particles are often quite small, typically ranging from
a few micrometres to a few hundred micrometres in size.
• Powder Blending: Different metal powders and additives may be blended together to create desired material properties or compositions. The
blending process ensures uniform distribution of the different powders.
• Compaction: The blended powder is placed into a mould or die cavity and subjected to high pressure. This pressure compacts the powder (Source of images:
particles, resulting in a green compact—a loosely held-together, porous shape that resembles the final part. https://www.capstan.com/powder-metal-
• Sintering: The green compact is heated in a controlled atmosphere, often in a furnace, to a temperature just below the melting point of the overview/)
metal. During sintering, the metal particles bond together through diffusion, and the compact undergoes significant shrinkage and
densification. The final part takes on its desired shape and gains improved mechanical properties.

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