Controlling Springback With Compensation Strategies

Weiher, J.; Rietman, Bert; Kose, Kim; Ohnimus, S.; Petzoldt, Martin

doi:10.1063/1.1766660

Cited by 32 publications

(11 citation statements)

References 1 publication

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“…This paper corresponds with the statement that springback phenomenon can currently be accurately analysed and compensated only on parts with a less complex shape. Through literature, most papers agree that various compensation strategies lead to an improvement in the inaccuracy by up to 70-80 % [10][11][12]. Similar but slightly better results have been achieved in the presented experiment.…”

Section: Comparison Of the Resultssupporting

confidence: 83%

Compensation of Springback in Large Sheet Metal Forming

2019

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A precise production of sheet metal parts has always been a main goal in press shops. Highest quality demands are required especially in automotive production. Unfortunately, even today, the production is not optimal due to an ineffective approach to the springback compensation. Springback results in geometrical shape inaccuracies of the obtained product. Based on the current approach, excessive time and financial costs emerge due to corrections on the press tools. However, these corrections do not always lead to a better accuracy of the stampings. The main objective of the research is to design a modified solution of the current approach. The modified solution is designed as a methodology with a focus on the analysis and compensation of the springback with a help of a numerical simulation. To achieve the main goal, smaller sub-goals are employed. These sub-goals, or rather experiments, mainly focus on parameters, which, more or less, influence the springback phenomenon. The designed methodology is verified with real car body parts and is carried out with a help of the department of the press tools design in ŠKODA AUTO, a.s. There, the methodology is used for improving the accuracy of the stamping process of the car body parts and for improving the quality of the final product.

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Section: Comparison Of the Resultssupporting

confidence: 83%

Compensation of Springback in Large Sheet Metal Forming

2019

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“…Some research have been conducted to reverse compensate the part geometry based on statistical measurement of deformation [21,22]. In other manufacturing processes such as sheet metal forming, a reverse compensation method in springback compensation proved to be effective, which is called "displacement adjustment" (DA) method [23,24]. The idea of DA method is to move the nodes of original STL surface in the opposite direction of deformation.…”

Section: Related Workmentioning

confidence: 99%

A Reverse Compensation Framework for Shape Deformation in Additive Manufacturing

Kwok

2016

Volume 2: Materials; Biomanufacturing; Properties, Applications and Systems; Sustainable Manufacturing

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Shape deformation is an important issue in additive manufacturing (AM) processes such as the projection-based Stereolithography. Volumetric shrinkage and thermal cooling during the photopolymerization process combined with other factors such as the layer-constrained building process lead to complex deformation that is difficult to predict and control. In this paper, a general reverse compensation method and related computation framework are presented to reduce the shape deformation of AM fabricated parts. During the reverse compensation process, the shape deformation is calculated based on physical measurements of shape deformation. A novel method for identifying the correspondence between the deformed shape and the given nominal computer-aided design (CAD) model is presented based on added markers. Accordingly, a new CAD model based on the shape deformation and related compensation is computed. The intelligently revised CAD model by going through the same building process can result in a fabricated part that is close to the nominal CAD model. Two test cases have been designed to demonstrate the effectiveness of the presented method and the related computation framework. The shape deformation in terms of L2- and L∞-norm based on measuring the geometric errors is reduced by 40–60%.

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“…Unfortunately, in the DA method, the compensation field is generally applied to the mesh nodes and this may give unacceptable tools or rough solutions in case of complex shapes [11]. To solve this problem, the Smooth DA method (SDA), or the Surface Controlled Overbending method (SCO), has been proposed [12] and successfully applied also to industrial case studies [13]. The SDA applies the DA formulation on an analytical approximation of the discrete mesh that is made according to polynomial basis-functions of x, y, z, while, in the SCO, the shape modifications are applied to the control points of NURBS surfaces that represent the CAD models of the component and the die [14].…”

Section: Introductionmentioning

confidence: 99%

Robust Die Compensation in Sheet Metal Design through the Integration of Dual Response Surface and Shape Function Optimization

Bici

Campana

Cimolin³

et al. 2019

Mathematical Problems in Engineering

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In sheet metal forming, springback represents a major drawback increasing die set-up problems, especially for ultra-high strength steels. Finite Element Analysis is a well-established method to simulate the process during design, and multicriteria optimizations, for example, via surrogate models, are investigated in order to develop integrated design. Since to take into account also springback compensation die design may involve a large number of geometric variables, this paper presents a robust design formulation, based on the adoption of the shape function optimization, to describe springback in terms of weights directly associated to global shape variations of the die shape. Doing so, multicriteria optimization, which involves also die compensation, can be set up in a more intuitive approach, as requested in the preliminary steps of die design. After the introduction of the industrial problem, the mathematical formulation of the shape function optimization is presented together with its novel extension to Robust Design, which is based on the Dual Response Surface. Through a test case derived from the head part of a B-pillar, stamped from a Dual Phase sheet 1.5 mm thick, this novel extension investigates the effect of 6% variation from nominal values of initial yield stress and thickness. Results demonstrate the feasibility of the procedure, underlying that an optimal compensation may not be optimal in terms of process robustness.

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Controlling Springback With Compensation Strategies

Cited by 32 publications

References 1 publication

Compensation of Springback in Large Sheet Metal Forming

Compensation of Springback in Large Sheet Metal Forming

A Reverse Compensation Framework for Shape Deformation in Additive Manufacturing

Robust Die Compensation in Sheet Metal Design through the Integration of Dual Response Surface and Shape Function Optimization

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