mechanik-science.com MECHANIK 2/2019 How to cite this article: Authors: Paweł Bałon, Bartłomiej Kiełbasa, Edward Rejman, Robert Smusz, Janusz Szostak Title of article: “Forming containers for PCM materials using a hydrotechnical method with an elastomer” Mechanik, No. 2 (2019) DOI: https://doi.org/10.17814/mechanik.2019.2.20 Forming containers for PCM materials using a hydrotechnical method with an elastomer PAWEŁ BAŁON BARTŁOMIEJ KIEŁBASA EDWARD REJMAN ROBERT SMUSZ JANUSZ SZOSTAK * * Dr inż. Paweł Bałon, p.balon@szel-tech.pl –SZEL-TECH Szeliga Grzegorz, AGH w Krakowie, Polska Mgr inż. Bartłomiej Kiełbasa, bartek.kielbasa@gmail.com – SZEL-TECH Szeliga Grzegorz; Dr inż. Edward Rejman, erejman@prz.edu.pl – Politechnika Rzeszowska, Polska Dr inż. Robert Smusz, robsmusz@gmail.com – Politechnika Rzeszowska, Polska Dr inż. Janusz Szostak, szostak@agh.edu.pl – AGH w Krakowie, Polska In this work, the authors present the method of forming by oil exerting pressure on the elastic punch forming the shape of a container for phase change material (PCM). Thanks to the use of two elastomer plates with a hardness of 65 and 80 Shore, the obtained part has mapped stiffeners in the middle and the appropriate depth of the bowl. This method is not widespread due to the precise design ensuring tightness of the load system of the formed blank. By reducing the tool costs, this method is used in particular in the case of unit production of prototype parts or small production series. The authors carried out tests of mechanical properties of the material, numerical analysis of feasibility with the FEM, real (workshop) trials after previous optimization by trial and error through structural changes of the tool. This allowed to obtain the best material drawing parameters for given boundary conditions. The research allowed to eliminate significant stresses and thinning in finished parts and corners of PCM containers. KEYWORDS: stamping, forming, elastic punch, rubber forming Introduction Stamping processes with tools using elastomeric punches, especially rubber ones, are used primarily in unit and small-lot production. Complex shapes of manufactured products usually require expensive and specialized equipment. The advantage of using a flexible stamp is that a rigid die (steel or other material) is sufficient to make the stamping on the press, while the role of the stamp is played by a rubber or elastomeric spacer that adapts to the assumed shape. This allows to reduce tool costs by half and reduce the time to manufacture shaping elements. Forming processing of sheets with the use of an elastic punch, also known as the universal punch method, offers many different forming possibilities. Flexible stamping dies supplement the forming methods with a steel rigid punch (or rigid die). The forming material can be rubber, elastomer, liquid (water or oil) or simultaneously elastomer and forming liquid. The use of hydrotechnical plastic forming (with the simultaneous use of an elastomer diaphragm and oil) is limited to forming bowl-type elements, while the method of pressing with the elastomer alone has no major restrictions. It should be mentioned that elastomer (especially rubber) can be used as an auxiliary element in the shaping process by other methods, e.g. as a pressure or filler preventing sheet cracking and folding. The main advantage of all elastomer molding methods is making the machining process independent of sheet thickness tolerance. It is also possible to shape sheets of variable thickness, so-called taylored blank method [7].