Simulation of springback

Spring-back evaluation of automotive sheets based on isotropic–kinematic hardening laws and non-quadratic anisotropic yield functions, part III: applications

Study on the influence of work-hardening modeling in springback prediction

Part shape error due to springback can be a manufacturing defect in sheet metal forming processes. This manufacturing problem can be corrected by using appropriate designs of the tooling and the binder shape together with a binder constraint. In the present work a methodology for tool and binder design based on inverse springback calculations is developed and demonstrated. The design procedure invokes finite element analysis of the manufacturing process. The proposed method was demonstrated for two cases of forming of channel geometries (two-dimensional and three-dimensional) with an aluminum alloy sheet. The tooling needed to form the desired parts was numerically designed using the proposed algorithm then constructed with the aid of CNC machining. The designed tooling was found to produce the desired part shapes demonstrating both the accuracy of the numerical simulations and the success of the proposed tooling design algorithm.

Tooling and binder design for sheet metal forming processes compensating springback error

Metal forming processes operate in conditions of uncertainty due to parameter variation and imperfect understanding. This uncertainty leads to a degradation of product properties from customer specifications, which can be reduced by the use of closed-loop control. A framework of analysis is presented for understanding closed-loop control in metal forming, allowing an assessment of current and future developments in actuators, sensors and models. This leads to a survey of current and emerging applications across a broad spectrum of metal forming processes, and a discussion of likely developments.

Closed-loop control of product properties in metal forming

Mathematical modeling of plane-strain bending of sheet and plate

Practical die design via section analysis

Estimation and Control of Drawbead Forces in Sheet Metal Forming

Process Simulation and Springback Control in Plane Strain Sheet Bending

Square-punch forming: Experiments and simulations in two and three dimensions

Chuan-Tao Wang

Papers

Mathematical modeling of plane-strain bending of sheet and plate

Practical die design via section analysis

Estimation and Control of Drawbead Forces in Sheet Metal Forming

Process Simulation and Springback Control in Plane Strain Sheet Bending

Square-punch forming: Experiments and simulations in two and three dimensions