New method for springback compensation for the stamping of sheet metal components

Birkert, Arndt; Hartmann, B.; Straub, Michael

doi:10.1088/1742-6596/896/1/012067

Cited by 8 publications

(8 citation statements)

References 6 publications

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“…The production process of the fender has been simulated with the FE-Software AutoForm R8. To compensate the tool geometries, the Physical Compensation Method [6] has been used. 8.…”

Section: Figure 3 Simulation Setups and Theoretical Results By Applyi...mentioning

confidence: 99%

Advanced Springback Compensation Strategy through elimination of avoidable elastic strain energy

Birkert

Zimmermann

Hartmann

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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The stamping of dimensionally accurate sheet metal body components still represents a huge challenge in the automotive industry. This is partly caused by the multi-stage production process which complicates the design of an appropriate compensation strategy dramatically. A key prerequisite of an appropriate compensation strategy is to eliminate any undesired influence of elastic energy being potentially induced when closing the blankholders in the several operations throughout the production process. Here, a universally applicable compensation strategy is presented which fulfils this requirement thoroughly; by applying this process, the involved strain energy is reduced to a minimum due to proper part position in all operations. Technically this compensation strategy is achieved by, first, simulating all operations of the stamping process individually, second, by individually calculating the springback after each operation and, third, by accumulating the calculated deviation vector fields for each operation appropriately, which are then used for springback compensation. The process is time and cost effective and the required efforts are moderate even for complicated multistage stamping operations.

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“…The production process of the fender has been simulated with the FE-Software AutoForm R8. To compensate the tool geometries, the Physical Compensation Method [6] has been used. 8.…”

Section: Figure 3 Simulation Setups and Theoretical Results By Applyi...mentioning

confidence: 99%

Advanced Springback Compensation Strategy through elimination of avoidable elastic strain energy

Birkert

Zimmermann

Hartmann

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

Self Cite

View full text Add to dashboard Cite

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“…These methods are based on a mathematical inversion of the springback vector field to generate the compensation vector field. A method that differs from the methods mentioned is the so-called Physical Compensation Method (PC-Method) [12]. With this method, the vertical deviations between the part after springback and the target part geometry is used to generate the compensation vector field by overbending the target part geometry in a separate FE simulation.…”

Section: State-of-the-art Springback Compensation Methods and Approachesmentioning

confidence: 99%

Holistic springback compensation procedure

Zimmermann,

Birkert,

Saup

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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The elastic springback during the manufacturing process of stamped car body components causes dimensional deviations. To compensate these deviations, the common approach is to modify the tool surfaces in the opposite direction of the deviations – this is called springback compensation. In the procedure of springback compensation various issues must be solved. To achieve the main goal of a dimensionally accurate part, it must be ensured that, on the one hand the distance normal to the sheet surface between the springback part and the target geometry is within a specified dimensional tolerance. On the other hand, it must be ensured that the surface areas and characteristic lengths of the springback part and that of the target geometry match as closely as possible. In the past, approaches/methods, such as the physical compensation method and the physical scaling approach, have been presented which can successfully counteract these problems. Furthermore, in a multi-stage process in subsequent operations a stable part position must be achieved and unwanted plastic deformations must be avoided during blankholder closing. Therefore, different compensation strategies have been presented, which can fulfil these requirements. However, in the publication of these methods, the problems were always considered individually. This paper shows how all the named requirements can be achieved by combining the individual methods in springback compensation.

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“…The geometrically-based Displacement-Adjustment method (DA) was established by Gan and Wagoner [14] and consists in displacing the deviating nodes by the exact amount of the calculated deviations. The superior convergence behaviour of such technique has been proved by Lingbeeck [15], while Birkert [16] investigated the impact of the compensation direction. The definition of the springback driving stress as the difference between residual and forming stresses is the core of the springback cause analysis method by Hiramoto [17].…”

Section: State Of the Artmentioning

confidence: 99%

Development of a numerical compensation framework for geometrical deviations in bulk metal forming exploiting a surrogate model and computed compatible stresses

et al. 2021

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The optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

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New method for springback compensation for the stamping of sheet metal components

Cited by 8 publications

References 6 publications

Advanced Springback Compensation Strategy through elimination of avoidable elastic strain energy

Advanced Springback Compensation Strategy through elimination of avoidable elastic strain energy

Holistic springback compensation procedure

Development of a numerical compensation framework for geometrical deviations in bulk metal forming exploiting a surrogate model and computed compatible stresses

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