Manufacturing the round hat section by PVC Teflon-pad forming process

Teflon-pad forming process is a diverse method to form different materials and profiles that are used in aerospace, automotive and military industries. In this study, the Teflon-pad forming process is performed to produce a round hat section profile. For this purpose, some thin-walled circular metal tubes were prepared. Then, they compressed between a rigid U-shape die and a rigid platen, laterally. For manufacturing the round hat section profiles, circular tubes from brass alloy and a PVC Teflon pad as the filler are used. Effects of geometrical properties of circular tubes and PVC Teflon are investigated on the forming process. Also, diagrams of forming energy of the produced profiles are sketched to compare the effects of different parameters on the shaping process. According to the profile final cross-section, some deviation parameters are defined to compare the produced round hat section structure with the desirable profile. The forming process is performed in two conditions; single and double-stage forming process. The results show that the double-stage forming process decreases total deviation of the profile 33.94-96.23 %, in comparison with the singlestage forming process. In addition, the results show that the manufactured round hat section profile has the suitable quality to use as a structural profile in different industries.