Springback
Compensation Process (SCP) is a module for calculation of springback
compensation of tools. Application of advanced sheet materials such as aluminum
alloy, high strength and ultra high strength steel helps to reduce body weight
of an automobile without sacrificing the safety performance. Increasing
application of advanced sheet materials to manufacture body of automobile has
also created several issues in metal stamping industry. One of the crucial
issues is the springback phenomenon as a result of elastic recovery of sheet
material and uneven stress distribution after forming.
Traditionally,
springback may be resolved in the shop floor by overcrown, overbend, restrike,
stiffening darts, etc. Today, stamping CAE software plays a significant role in
the prediction of springback of sheet metal components and compensation for
tooling to alleviate springback. Using stamping CAE software, the user can
conduct springback analysis and morphing of part after a sequence of process
such as draw, trimming and flanging. However, springback compensation
techniques are needed for users to compensate the original tooling surface to
resolve the springback phenomenon. For decades, the springback compensation is
performed depending on the experience of engineers. With advanced development
of computer hardware and software technology, springback compensation can be
quickly performed using CAE software such as eta/DYNAFORM.
In
eta/DYNAFORM, springback compensation can be performed to correct part shape
after springback to archive the dimension tolerance of intended part design. As
illustrated in Figure 10.16.1, springback compensation is
carried out after series of forming simulation and springback analysis.
Iterative compensation approach may be adopted to obtain reasonable compensated
tool surface.
SCP menu
illustrated in Figure 10.16.2 provides functions such as Compensation,
Result Check, Topology Repair, Morphing, Surface Mapping., Best Fit and Deviation
Check Detailed description of each function is given in the following sections.
Figure 10.16.1 Springback Compensation Procedure
Figure 10.16.2 SCP Menu