A new iterative method for springback control based on theory analysis and displacement adjustment

Zhang, Zengkun; Wu, Jianjun; Zhang, Shen; Wang, Mingzhi; Guo, Ruichao; Guo, Shaochang

doi:10.1016/j.ijmecsci.2015.11.005

Cited by 29 publications

(15 citation statements)

References 20 publications

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“…19is calculate as From Eqs. (17) and (20), the curvature and bending angle meet the convergence criterion of the iterative parameter as shown in Eq. (2).…”

Section: Figure 4 Analytical Model Of V-free Bendingmentioning

confidence: 99%

“…Among them, the "Force Descriptor Method (FDM)" [12,13] and "Displacement Adjustment (DA) method" [1] have attracted researchers more attention for its directness and effectiveness. Recently, various methods have been reported based on the DA method or the FDM, such as the Smooth Displacement Adjustment (SDA) method and the Surface Controlled Overbending (SCO) method [14], the Accelerated Compensation (AC) method [15], the Comprehensive Compensation (CC) method [16], the Enhanced Displacement Adjustment (E-DA) method [17], the alternate Hybrid Method (HM) [18], the Discrete Curvature Adjustment (DCA) strategy [19], and the Sheet Elements Compensation (SEC) method [20]. Most of these methods are based on finite element simulation and focused on optimizing the compensation direction by the compensation factor as well as smoothing the plane by the function curve, to improve the compensation speed and convergence.…”

Section: Introductionmentioning

confidence: 99%

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An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application

Wang

Zhai

2019

Chin. J. Mech. Eng.

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In order to solve the springback problem in sheet metal forming, the trial and error method is a widely used method in the factory, which is time-consuming and costly for its non-direction and non-quantitative. Finite element simulation is an effective method to predict the springback of complex shape parts, but its precision is sensitive to the simulation model, particularly material model and boundary conditions. In this paper, the simple iterative method is introduced to establish the iterative compensation algorithm, and the convergence criterion of iterative parameters is put forward. In addition, the new algorithm is applied to the V-free bending and stretch-bending processes, and the convergence of curvature and bending angle is proved theoretically and verified experimentally. At the same time, the iterative compensation experiments for plane bending show that, the new method can predict the next compensation value based on the springback of each test, so that the target bending angle with the error of less than ± 0.1% and the target curvature with the error of less than 0.5% are obtained after 2-3 iterations. This research proposes a new iterative compensation algorithm to predict springback in sheet metal forming process, where each compensation value depends only on the iteration parameter difference before and after springback for the same forming process of same material.

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“…19is calculate as From Eqs. (17) and (20), the curvature and bending angle meet the convergence criterion of the iterative parameter as shown in Eq. (2).…”

Section: Figure 4 Analytical Model Of V-free Bendingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application

Wang

Zhai

2019

Chin. J. Mech. Eng.

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“…Nowadays, the requirements of shape accuracy and manufacturing efficiency are increasing gradually. The springback deformation after forming makes the tool surface different from the part shape and should be compensated [7,9,31].…”

Section: Introductionmentioning

confidence: 99%

“…The principle of forming shape design is to measure the shape deviation between the formed part and the desired shape, and compensation would be made in the direction opposite to shape deviation. The process is repeated until the forming shape deviation attains a specified tolerance [7,9,31].…”

Section: Introductionmentioning

confidence: 99%

“…Compensation factor is used to adjust the theoretically compensated geometry to decrease the number of cycles [16,30]. For example, the improved sheet elements compensation (SEC) method still needs three iterations for continuous doubly curved bending shape less than 100 mm long [31]. As a result, and despite significant research efforts to date, the application of FE analysis to predict shape geometric deviations caused by springback is still very limited [12].…”

Section: Introductionmentioning

confidence: 99%

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A rapid and intelligent approach to design forming shape model for precise manufacturing of flanged part

Liu

Yang

et al. 2017

Int J Adv Manuf Technol

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Adjusting the part shape with complex flanges to compensate springback deformation is key to forming shape design for manufacturing rapidly and precisely. Classical forming shape design by displacement adjustment (DA) method using finite element (FE) simulation is usually time-consuming and not accurate enough for complex surface part in industrial application. In this paper, the forming shape is modeled by changing the relations of geometric features of part model with the new flange control surfaces directly. Control surface processing (CSP) method is presented including control surface trimming, cross section division, springback compensation, and extending to design forming shape model of doubly curved flange part with joggles rapidly. The algorithms of cross section curves division of control surfaces and subsequent subdivision of each curve with circular arc and line segments are proposed. A case-based reasoning (CBR) technique and gray relation analysis (GRA) are used to support the intelligent springback prediction of each bending segment of the cross section curve. The geometric data of control surface is expressed in XML format to realize the integration of the CAD-based tools of control surface division and compensation with the Web-based springback prediction system. The approach is demonstrated on an industrial aircraft wing rib part. The forming shape model could be designed rapidly by comparison with DA method. The part shape deviations of flange angle (−0.465°~0.528°) and surface position (−0.3 mm~0.3 mm) were detected by comparing the desired geometry with the actual digital formed part shape, and the results indicate that the approach can achieve the industrial part manufacturing rapidly and precisely.

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A deformation compensation method for wax pattern die of turbine blade

Jiang

Zhang

et al. 2016

Int J Adv Manuf Technol

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A new iterative method for springback control based on theory analysis and displacement adjustment

Cited by 29 publications

References 20 publications

An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application

An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application

A rapid and intelligent approach to design forming shape model for precise manufacturing of flanged part

A deformation compensation method for wax pattern die of turbine blade

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