Springback analysis and strategy for multi-stage thin-walled parts with complex geometries

Abstract

Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work. The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters. Furthermore, in order to minimize the springback problem, an accurate springback simulation model of the part was established and validated. The effects of the element size and timesteps on springback model were further investigated. Results indicate that the custom mesh size is beneficial for the springback simulation, and the four timesteps are found suited for the springback analysis for the complex geometry part. Finally, a strategy for reducing the springback by changing the geometry of the blank is proposed. The optimal blank geometry is obtained and used for manufacturing the part.

Keywords

springback model / complex geometry / multi-stage / rigid-flexible compound process

References

[1] WagonerR H, LiM. Simulation of springback: through-thickness integration [J]. International Journal of Plasticity, 2007, 23(3): 345-360

[2] LiJ, ZhaoJ, SunH-l, MaRui. Improvement of springback prediction of wide sheet metal air bending process [J]. Journal of Central South University of Technology, 2010, 15(S2): 310-315

[3] ClevelandM, GhoshA K. Inelastic effects on springback in metals [J]. International Journal of Plasticity, 2002, 18: 769-785

[4] HanF, MoJ-h, GongP, LiMin. Method of closed loop springback compensation for incremental sheet forming process [J]. Journal of Central South University of Technology, 2011, 18(5): 1509-1517

[5] DaxinE, LiuY. Springback and time-dependent springback of 1Cr₁₈Ni₉Ti stainless steel tubes under bending [J]. Materials & Design, 2010, 31(3): 1256-1261

[6] GengL, WagonerR H. Role of plastic anisotropy and its evolution on springback [J]. International Journal of Mechanical Sciences, 2002, 44(1): 123-148

[7] ChattiS, HermesM, WeinrichA, Ben-KhalifaN, TekkayaA E. New incremental methods for springback compensation by stress superposition [J]. International Journal of Material Forming, 2009, 2(1): 817-820

[8] LingbeekR, HuetinkJ, OhnimusS, PetzoldtM, WeiherJ. The development of a finite elements based springback compensation tool for sheet metal products [J]. Journal of Materials Processing Technology, 2005, 169(1): 115-125

[9] XiangA-y, FengRuan. A die design method for springback compensation based on displacement adjustment [J]. International Journal of Mechanical Sciences, 2011, 53(5): 399-406

[10] WangH, ZhouJ, ZhaoT-s, TaoY-ping. Springback compensation of automotive panel based on three-dimensional scanning and reverse engineering [J]. International Journal of Advanced Manufacturing Technology, 2015, 85(5): 1187-1193

[11] LeeJ H, YoonJ S, RyuC H, KimS H. Springback compensation based on finite element for multipoint forming in shipbuilding [J]. Advanced Materials Research, 2007, 26-28: 981-984

[12] PreteA D, PrimoT, StranoM. The use of FEA packages in the simulation of a drawing operation with springback, in the presence of random uncertainty [J]. Finite Elements in Analysis & Design, 2010, 46(7): 527-534

[13] LangL H, JoachimD, KarlB N. Investigation into the effect of pre-bulging during hydromechanical deep drawing with uniform pressure onto the blank [J]. International Journal of Machine Tools & Manufacture, 2004, 44(6): 649-657

[14] TakahashiY, IharaT, KanazawaK. Fracture morphology accompanying fish-eye of austenitic stainless steel SUS321-B under long fatigue life region at 700 °C [J]. Transactions of Japan Society of Spring Engineers, 2014, 2014(59): 19-28

[15] TakahashiY, KobayashiM, KanazawaK. Stepwise S-N curve and internal fracture of austenitic stainless steel under high temperature and high cycle fatigue conditions [J]. Journal of the Society of Materials Science Japan, 2013, 62(2): 99-104

[16] AsgariA, PereiraM, RolfeB, DingleM, HodgsonP. Design of experiments and springback prediction for AHSS automotive components with complex geometry [J]. Electronic Notes in Discrete Mathematics, 2005, 50: 175-180

[17] AnderssonA. Numerical and experimental evaluation of springback in advanced high strength steel [J]. Journal of Materials Engineering & Performance, 2007, 16(3): 301-307

[18] SlotaJ, JurcisinM. Experimental and numerical prediction of springback in V-bending of anisotropic sheet metals for automotive industry [J]. Journal of Applied Physiology, 2012, 84(3/12): 55-68

[19] PapadiaG, PreteA D, AnglaniA. Experimental springback evaluation in hydromechanical deep drawing (HDD) of large products [J]. Production Engineering, 2012, 6(2): 117-127

[20] HarrisonD K, CheshireD G, BainesT S, VitanovV I. A methodology for the manufacture of forming tools incorporating complex surface geometry with minimum computer resources [J]. Journal of Materials Processing Technology, 1992, 31: 103-111

[21] ZHAO Dong-xu. The numerical simulation and technology optimization of the stamping forming of automotive lightweight steel and springback characteristics [D]. Changchun, China: Jilin University, 2007. (in Chinese)

[22] ZhangX-j, ZhouX-bin. Simulation of springback in sheet metal forming [J]. Journal of Plasticity Engineering, 1999, 6(3): 56-62