A novel approach of springback analysis using a drawbead and a die shoulder database in sheet metal forming simulation

Abstract

Springback in sheet metal forming is a deformation that occurs when a workpiece is released from dies after forming. Prediction of springback using the finite element method (FEM) has been used in the design of stamping dies. The present paper describes an effective approach by which to improve the accuracy of springback analysis, which can also suppress the increase in the calculation time. In general, FEM using the analysis condition to decrease discretization errors greatly increases the computation time. The proposed procedure is as follows: (1) Quick analysis using a large mesh size is performed. (2) Data mapping and morphology mapping for the forming results are then performed using the database based on a detailed partial analysis of the drawbead and the die shoulder. (3) Springback analysis is performed using the forming results modified by the data mapping and morphology mapping. A forming experiment was conducted to confirm that the proposed method using the database greatly improves the prediction accuracy of the shape after springback and also suppresses the increase in calculation time.

Stamping Tools for Sheet Metal Forming: Current State and Future Research Directions

“…The use of sub-modelling is recommended as the way to transfer the deformed shapes. To increase the accuracy of springback analysis without greatly increasing the solution time of the FE-models, Iwata and Iwata [16] proposed a method where a refined model of the drawbead and die shoulder is made separately and the results saved in a database. The data is then combined with the results of a conventional forming analysis and used to get a more accurate springback analysis.…”

Experimental Investigation of Drawbead Effect on Springback in Profile of Double Circular, Rectangular and Triangular Bending Sheet Metal Forming Processes

“…The changing of these radii will result in an important deformation in forming redundancy and springback. Iwata and Iwata (2018) studied the springback using FEM method and described an effective approach by which to improve the accuracy of springback analysis. Springback analysis is performed using the forming results modified by the data mapping and morphology mapping.…”