Numerical simulation of sheet stamping process using flexible punch

Abstract Different from the conventional stamping process, rubber forming uses a rubber pad contained in a rigid box to act as a punch. The main attraction of the process is its simplicity, and it can be used for prototype development or for low-volume production. In this study, an axisymmetric rubber-pad forming operation is investigated via numerical simulations and experiments. Some key process parameters, such as rubber material, hardness of flexible punch, stamping velocity, rubber-pad thickness, and friction are studied in detail. Good correlation is achieved between the finite element predicted and experimentally measured thickness—thinning in the formed part. Stress and strain distributions in the specimen are investigated numerically during the process using ABAQUS/Standard.