Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was pro...Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters.Furthermore,in order to minimize the springback problem,an accurate springback simulation model of the part was established and validated.The effects of the element size and timesteps on springback model were further investigated.Results indicate that the custom mesh size is beneficial for the springback simulation,and the four timesteps are found suited for the springback analysis for the complex geometry part.Finally,a strategy for reducing the springback by changing the geometry of the blank is proposed.The optimal blank geometry is obtained and used for manufacturing the part.展开更多
Fixed-appliance technology is the most common and effective malocclusion orthodontic treatment method, and its key step is the bending of orthodontic archwire. The springback of archwire did not consider the movement ...Fixed-appliance technology is the most common and effective malocclusion orthodontic treatment method, and its key step is the bending of orthodontic archwire. The springback of archwire did not consider the movement of the stress-strain-neutral layer. To solve this problem, a spring- back calculation model for rectangular orthodontic archwire is proposed. A bending springback experiment is conducted using an orthodontic archwire bending springback mea- surement device. The springback experimental results show that the theoretical calculation results using the proposed model coincide better with the experimental testing results than when movement of the stress-strain-neutral layer was not considered. A bending experiment with rectangular orthodontic archwire is conducted using a robotic orthodontic archwire bending system. The patient expriment result show that the maximum and minimum error ratios of formed orthodontic archwire parameters are 22.46% and 10.23% without considering springback and are decreased to 11.35% and 6.13% using the proposed model. The proposed springback calculation model, which considers the move- ment of the stress-strain-neutral layer, greatly improves the orthodontic archwire bending precision.展开更多
Iterative methods based on finite element simulation are effective approaches to design mold shape to compensate springback in sheet metal forming. However, convergence rate of iterative methods is difficult to improv...Iterative methods based on finite element simulation are effective approaches to design mold shape to compensate springback in sheet metal forming. However, convergence rate of iterative methods is difficult to improve greatly. To increase the springback compensate speed of designing age forming mold, process of calculating springback for a certain mold with finite element method is analyzed. Springback compensation is abstracted as finding a solution for a set of nonlinear functions and a springback compensation algorithm is presented on the basis of quasi Newton method. The accuracy of algorithm is verified by developing an ABAQUS secondary development program with MATLAB. Three rectangular integrated panels of dimensions 710 mmx750 mm integrated panels with intersected ribs of 10 mm are selected to perform case studies. The algorithm is used to compute mold contours for the panels with cylinder, sphere and saddle contours respectively and it takes 57%, 22% and 33% iterations as compared to that of displacement adjustment (DA) method. At the end of iterations, maximum deviations on the three panels are 0.618 4 mm, 0.624 1 mm and 0.342 0 mm that are smaller than the deviations determined by DA method (0.740 8 mm, 0.740 8 mm and 0.713 7 mm respectively). In following experimental verification, mold contour for another integrated panel with 400 ram^380 mm size is designed by the algorithm. Then the panel is age formed in an autoclave and measured by a three dimensional digital measurement devise. Deviation between measuring results and the panel's design contour is less than 1 mm. Finally, the iterations with different mesh sizes (40 mm, 35 mm, 30 mm, 25 mm, 20 mm) in finite element models are compared and found no considerable difference. Another possible compensation method, Broyden-Fletcher-Shanmo method, is also presented based on the solving nonlinear fimctions idea. The Broyden-Fletcher-Shanmo method is employed to compute mold contour for the second panel. It only takes 50% iterations compared to that of DA. The proposed method can serve a faster mold contour compensation method for sheet metal forming.展开更多
Springback is one of important factors influencing the forming quality of numerical control (NC) bending of thin-walled tube. In this paper, a numerical-analytic method for springback angle prediction of the process...Springback is one of important factors influencing the forming quality of numerical control (NC) bending of thin-walled tube. In this paper, a numerical-analytic method for springback angle prediction of the process was put forward. The method is based on springback angle model derived using analytic method and simulation results from three-dimensional (3D) rigid-plastic finite element method (FEM). The method is validated through comparison with experimental results. The features of the method are as follows: (1) The method is high in efficiency because it combines advantages of rigid-plastic FEM and analytic method. (2) The method is satisfactory in accuracy, since the field variables used in the model is resulting from 3D rigid-plastic FEM solution, and the effects both of axial force and strain neutral axis shift have been included. (3) Research on multi-factor effects can be carried out using the method due to its advantage inheriting from rigid-plastic FEM. The method described here is also of general significance to other bending processes.展开更多
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...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 e ective 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 compensaantido tnh ev atlaureg ebta cseurdv oatnu trhe ew sitphri tnhgeb earcrko ro fo fe laecshs ttehsat,n s0 o. 5 th%a ta rteh eo btatraigneet db aefntedri n2 g-3 a nitgelrea tiwoitnhs.t Thhei se rrreosre aorf clhe sps rtohpaons e±s 0 a.1%new iterative compensation algorithm to predict springback in sheet metal forming process, where each compensation value depends only on the iteration parameter di erence before and after springback for the same forming process of same material.展开更多
Transformation-induced plasticity(TRIP)steel possesses high strength and formability,enabling the use of a thinner gauge material and allowing for the fabrication of complex shapes.In this research,we measured the eff...Transformation-induced plasticity(TRIP)steel possesses high strength and formability,enabling the use of a thinner gauge material and allowing for the fabrication of complex shapes.In this research,we measured the effect of bending temperatures on the microstructure and air-bending springback angle of TRIP steel at temperatures from 25 to 600C.Real-time in situ X-ray diffraction and scanning electron microscopy were used for pre-and postbending analysis.As the prebending temperature increased from 25C to 600C,the retained austenite(RA)volume fraction decreased,and the RA transformed to bainite at temperatures above 400C.The springback angle was positively correlated with the prebending RA volume fraction,with the smallest springback angle achieved at 400C.Additionally,the springback angle was positively correlated with the bending angle,because the RA transformation ratio contributed to increased strain hardening.Further microstructure analysis revealed that the RA became elongated in the tension direction as the bending temperatures increased.展开更多
Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending spr...Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending springback of typical U-pattern is studied. At the same time the springback values of the drawing of patterns' unloading and trimming about the satellite aerial reflecting surface are predicted and also compared with those of the practical punch. Above two springbacks all obtain satisfactory results, which provide a kind of effective quantitative pre-prediction of springback for the practical engineers.展开更多
Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback predicti...Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback prediction in stretch bending forming mainly focuses on artificial neural networks combined with the finite element simulation. There is a lack of springback prediction by support vector regression(SVR). In this paper, SVR is applied to predict springback in the three-dimensional stretch bending forming process, and variable stretch force trajectory is optimized. Six parameters of variable stretch force trajectory are chosen as the input parameters of the SVR model. Sixty experiments generated by design of experiments(DOE) are carried out to train and test the SVR model. The experimental results confirm that the accuracy of the SVR model is higher than that of artificial neural networks. Based on this model, an optimization algorithm of variable stretch force trajectory using particle swarm optimization(PSO) is proposed. The springback amount is used as the objective function. Changes of local thickness are applied as the criterion of forming constraints. The objection and constraints are formulated by response surface models. The precision of response surface models is examined. Six different stretch force trajectories are employed to certify springback reduction in the optimum stretch force trajectory, which can efficiently reduce springback. This research proposes a new method of springback prediction using SVR and optimizes variable stretch force trajectory to reduce springback.展开更多
This work deals with a reliability assessment of springback problem during the sheet metal forming process. The effects of operative parameters and material properties, blank holder force and plastic prestrain, on spr...This work deals with a reliability assessment of springback problem during the sheet metal forming process. The effects of operative parameters and material properties, blank holder force and plastic prestrain, on springback are in- vestigated. A generic reliability approach was developed to control springback. Subsequently, the Monte Carlo simula- tion technique in conjunction with the Latin hypercube sam- pling method was adopted to study the probabilistic spring- back. Finite element method based on implicit/explicit al- gorithms was used to model the springback problem. The proposed constitutive law for sheet metal takes into account the adaptation of plastic parameters of the hardening law for each prestrain level considered. Rackwitz-Fiessler al- gorithm is used to find reliability properties from response surfaces of chosen springback geometrical parameters. The obtained results were analyzed using a multi-state limit reli- ability functions based on geometry compensations.展开更多
Springback is considered to be one of the most important problems in aluminum sheet stamp forming, leading to deviation from the designed target shape and assembly defects. In this study, a springback simulation model...Springback is considered to be one of the most important problems in aluminum sheet stamp forming, leading to deviation from the designed target shape and assembly defects. In this study, a springback simulation model based on the benchmark of a Jaguar Land Rover aluminum panel is established. We embed several elastoplastic constitutive models ( Barlat' s 89, Barlat' s YLD2000, Yoshida-Uemori (YU) + Barlat' s 89, and YU + Barlat' s YLD2000) in the finite element model,in order to discuss the influence of the constitutive model selection on springback prediction in aluminum sheet forming.展开更多
The forming of sheet metal in a desired and attractive shape is a process that requires an understanding of materials, mechanics and manufacturing principles. Manufacturing a consistent sheet metal component is challe...The forming of sheet metal in a desired and attractive shape is a process that requires an understanding of materials, mechanics and manufacturing principles. Manufacturing a consistent sheet metal component is challenging due to the nonlinear interactions of various material and process parameters. One of the major issues in the manufacturing of inconsistent?sheet metal?parts is springback. Springback is the elastic strain recovery in the material after the tooling is removed and the final shape of the product depends on the springback amount formed. In this study according to the result of simulation the inverted compensation method is adopted to optimize die surface design. Similarly, to predict and compensate the springback error this study presented an analytical approach of forming process in a stepwise modification of the automobile roof panel. Moreover, based on?Dynaform?and?finite element analysis of sheet metal stamping simulation the sprinback in automobile roof panel is predicted and compensated.?In addition, this study examines the significant requirements of the sheet metal forming precision of automobile body and the simulation of forming, stamping and springback of automobile roof panel is carried out, and the result of simulation also is analyzed.展开更多
Accurate springback prediction of wide sheet metal air bending process is important to improve product quality and ensure the precision in dimension. The definition of elastic limit bend angle was proposed. Based on c...Accurate springback prediction of wide sheet metal air bending process is important to improve product quality and ensure the precision in dimension. The definition of elastic limit bend angle was proposed. Based on cantilever beam elastic deforming theory, the geometrical parameters of forming tools, sheet thickness and the material yielding strain were derived and validated by the finite element method (FEM). Employing the degree of elastic limit bend angle, the equation for springback prediction was constructed, the results calculated fit well with experimental data. Especially for the small bend angle, the predicted results by equation were applied to conduct the springback prediction and compensation in industries and give closer correlation to the experimental data than those calculated by engineering theory of plastic bending.展开更多
The springback phenomenon of strong anisotropic sheet metals with U-channel bending as well as deep-drawing is numerically studied in detail by using Updating Lagrange FEM based on virtual work-rate principle, Kirchho...The springback phenomenon of strong anisotropic sheet metals with U-channel bending as well as deep-drawing is numerically studied in detail by using Updating Lagrange FEM based on virtual work-rate principle, Kirchhoff shell element models and the Barlat-Lian planar anisotropic yield function. Simulation results are compared with a benchamark test. Very good agreement is obtained between numerical and test results. The focus of the present study is on the numerical simulation of the springback characteristics of the strong anisotropic sheet metals after unloading. The effects of the planar anisotropy coefficients and yield function exponent in the B-L yield function on the springback characteristics are discussed in detail. Some conclusions are given.展开更多
A new method was worked out to improve the precision of springback prediction in sheet metal forming by combining the finite element method (FEM) with the data mining (DM) technique. First the genetic algorithm (GA) w...A new method was worked out to improve the precision of springback prediction in sheet metal forming by combining the finite element method (FEM) with the data mining (DM) technique. First the genetic algorithm (GA) was adopted for recognizing the material parameters. Then according to the even design idea, the suitable calculation scheme was confirmed, and FEM was used for calculating the springback. The computation results were compared with experiment data, the difference between them was taken as source data, and a new pattern recognition method of DM called hierarchical optimal map recognition method (HOMR) is applied for summarizing the calculation regulation in FEM. At the end, the mathematics model of the springback simulation was established. Based on the model, the calculation errors of springback can be controlled within 10% compared with the experimental results.展开更多
The objective of the present paper is to introduce a theoretical analysis of bending I-sections after pure bending. The springback values are determined to provide a quantitative method for predicting the springback u...The objective of the present paper is to introduce a theoretical analysis of bending I-sections after pure bending. The springback values are determined to provide a quantitative method for predicting the springback using von Mises criteria. The analytical methods for the I-section are given for two cases according to the positions of the yield point along the height of the beam. The controlling parameters on the springback of I-sections are studied. The results obtained are quite successful for the prediction of springback for bending I-sections.展开更多
Sheet metal single point incremental forming (SPIF) is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of t...Sheet metal single point incremental forming (SPIF) is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of the part are analysed using simple experimental method. Tool diameter, sheet thickness, step size, material parameters and the interaction of them are also analysed by using orthogonal test. The results show that the primary factor af- fecting springback is forming angle. In addition, springback is decreased when the specimen has a larger forming angle. The order of the four factors that influence springback is tool diameter, sheet thickness, step size and material parameters. The forming precision will increase if springabck is decreased by optimizing the forming parameters.展开更多
An optimization method was presented for cold stretch forming of titanium-alloy aircraft skin to determine process parameters and to reduce springback.In the optimization model,a mathematical formulation of stress dif...An optimization method was presented for cold stretch forming of titanium-alloy aircraft skin to determine process parameters and to reduce springback.In the optimization model,a mathematical formulation of stress difference was developed as an indicator of the degree of springback instead of implicit springback analysis.Explicit finite element method(FEM)was used to analyze the forming process and to provide the stress distribution for calculating the amount of the stress indicator.In addition,multi-island genetic algorithm(MGA)was employed to seek the optimal loading condition.A case study was performed to demonstrate the potential of the suggested method.The results show that the optimization design of process parameters effectively reduces the amount of springback and improves the part shape accuracy.It provides a guideline for controlling springback in stretch forming of aircraft skin.展开更多
Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plan...Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.展开更多
The springback is one of the key factors which affect the forming quality of thin-walled tube NC precision bending. The elastic-plastic finite element method was proposed to study the springback process of thin-walled...The springback is one of the key factors which affect the forming quality of thin-walled tube NC precision bending. The elastic-plastic finite element method was proposed to study the springback process of thin-walled tube NC precision bending and the combination of dynamic explicit algorithm and the static implicit algorithm was proposed to solve the whole process of thin-walled tube NC precision bending. Then, the 3D elastic-plastic finite element model was established based on the DYNAFORM platform, and the model was verified to be reasonable. At last, the springback rule of thin-walled tube NC precision bending and the effect of geometry and material parameters on the springback rule of thin-walled tube NC precision bending were studied, which is useful to controlling the springback of thin-walled tube NC precision bending, and the numerical simulation method can be used to study other effect of parameters on the forming quality of thin-walled tube NC precision bending.展开更多
Stresses and deformation states of pipe bending are investigated under loading or unloading with various pipe materials, size, bending radius and deformation temperature. A theorem of springback of large diameter pipe...Stresses and deformation states of pipe bending are investigated under loading or unloading with various pipe materials, size, bending radius and deformation temperature. A theorem of springback of large diameter pipe bending is presented. The experiments are carried out with pipe materials of 20, 10CrMo910 and 12Cr1MoV steel. Results of computations are in good agreement with experiments.展开更多
基金Project(2014ZX04002041)supported by the National Science and Technology Major Project,ChinaProject(51175024)supported by the National Natural Science Foundation of China
文摘Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters.Furthermore,in order to minimize the springback problem,an accurate springback simulation model of the part was established and validated.The effects of the element size and timesteps on springback model were further investigated.Results indicate that the custom mesh size is beneficial for the springback simulation,and the four timesteps are found suited for the springback analysis for the complex geometry part.Finally,a strategy for reducing the springback by changing the geometry of the blank is proposed.The optimal blank geometry is obtained and used for manufacturing the part.
基金Supported by National Natural Science Foundation of China(Grant Nos.51205093,61403222)China Postdoctoral Science Foundation(Grant No.2016M591538)+1 种基金Heilongjiang Postdoctoral Science Foundation(Grant No.LBH-Z16091)Science Funds for the Young Innovative Talents of Harbin University of Science and Technology(Grant No.201509)
文摘Fixed-appliance technology is the most common and effective malocclusion orthodontic treatment method, and its key step is the bending of orthodontic archwire. The springback of archwire did not consider the movement of the stress-strain-neutral layer. To solve this problem, a spring- back calculation model for rectangular orthodontic archwire is proposed. A bending springback experiment is conducted using an orthodontic archwire bending springback mea- surement device. The springback experimental results show that the theoretical calculation results using the proposed model coincide better with the experimental testing results than when movement of the stress-strain-neutral layer was not considered. A bending experiment with rectangular orthodontic archwire is conducted using a robotic orthodontic archwire bending system. The patient expriment result show that the maximum and minimum error ratios of formed orthodontic archwire parameters are 22.46% and 10.23% without considering springback and are decreased to 11.35% and 6.13% using the proposed model. The proposed springback calculation model, which considers the move- ment of the stress-strain-neutral layer, greatly improves the orthodontic archwire bending precision.
文摘Iterative methods based on finite element simulation are effective approaches to design mold shape to compensate springback in sheet metal forming. However, convergence rate of iterative methods is difficult to improve greatly. To increase the springback compensate speed of designing age forming mold, process of calculating springback for a certain mold with finite element method is analyzed. Springback compensation is abstracted as finding a solution for a set of nonlinear functions and a springback compensation algorithm is presented on the basis of quasi Newton method. The accuracy of algorithm is verified by developing an ABAQUS secondary development program with MATLAB. Three rectangular integrated panels of dimensions 710 mmx750 mm integrated panels with intersected ribs of 10 mm are selected to perform case studies. The algorithm is used to compute mold contours for the panels with cylinder, sphere and saddle contours respectively and it takes 57%, 22% and 33% iterations as compared to that of displacement adjustment (DA) method. At the end of iterations, maximum deviations on the three panels are 0.618 4 mm, 0.624 1 mm and 0.342 0 mm that are smaller than the deviations determined by DA method (0.740 8 mm, 0.740 8 mm and 0.713 7 mm respectively). In following experimental verification, mold contour for another integrated panel with 400 ram^380 mm size is designed by the algorithm. Then the panel is age formed in an autoclave and measured by a three dimensional digital measurement devise. Deviation between measuring results and the panel's design contour is less than 1 mm. Finally, the iterations with different mesh sizes (40 mm, 35 mm, 30 mm, 25 mm, 20 mm) in finite element models are compared and found no considerable difference. Another possible compensation method, Broyden-Fletcher-Shanmo method, is also presented based on the solving nonlinear fimctions idea. The Broyden-Fletcher-Shanmo method is employed to compute mold contour for the second panel. It only takes 50% iterations compared to that of DA. The proposed method can serve a faster mold contour compensation method for sheet metal forming.
基金This work was supported by the National Natural Science Foundation of China for Distinguished Young Scholars (Grant No. 50225518)the Teaching and Research Award Program for 0utstanding Young Teachers in Higher Education Institution of M0E, PRCthe Aeronautical Science Foundation of China (Grant No. 04H53057).
文摘Springback is one of important factors influencing the forming quality of numerical control (NC) bending of thin-walled tube. In this paper, a numerical-analytic method for springback angle prediction of the process was put forward. The method is based on springback angle model derived using analytic method and simulation results from three-dimensional (3D) rigid-plastic finite element method (FEM). The method is validated through comparison with experimental results. The features of the method are as follows: (1) The method is high in efficiency because it combines advantages of rigid-plastic FEM and analytic method. (2) The method is satisfactory in accuracy, since the field variables used in the model is resulting from 3D rigid-plastic FEM solution, and the effects both of axial force and strain neutral axis shift have been included. (3) Research on multi-factor effects can be carried out using the method due to its advantage inheriting from rigid-plastic FEM. The method described here is also of general significance to other bending processes.
基金Supported by Hebei Provincial Natural Science Foundation of in China(Grant Nos.E2015203244,E2016203266)Program for the Youth Top-notch Talents of Hebei Province
文摘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 e ective 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 compensaantido tnh ev atlaureg ebta cseurdv oatnu trhe ew sitphri tnhgeb earcrko ro fo fe laecshs ttehsat,n s0 o. 5 th%a ta rteh eo btatraigneet db aefntedri n2 g-3 a nitgelrea tiwoitnhs.t Thhei se rrreosre aorf clhe sps rtohpaons e±s 0 a.1%new iterative compensation algorithm to predict springback in sheet metal forming process, where each compensation value depends only on the iteration parameter di erence before and after springback for the same forming process of same material.
基金This research was funded by Faculty of Engineering,King Mongkut’s Institute of Technology Ladkrabang.
文摘Transformation-induced plasticity(TRIP)steel possesses high strength and formability,enabling the use of a thinner gauge material and allowing for the fabrication of complex shapes.In this research,we measured the effect of bending temperatures on the microstructure and air-bending springback angle of TRIP steel at temperatures from 25 to 600C.Real-time in situ X-ray diffraction and scanning electron microscopy were used for pre-and postbending analysis.As the prebending temperature increased from 25C to 600C,the retained austenite(RA)volume fraction decreased,and the RA transformed to bainite at temperatures above 400C.The springback angle was positively correlated with the prebending RA volume fraction,with the smallest springback angle achieved at 400C.Additionally,the springback angle was positively correlated with the bending angle,because the RA transformation ratio contributed to increased strain hardening.Further microstructure analysis revealed that the RA became elongated in the tension direction as the bending temperatures increased.
基金This project is supported by National Natural Science Foundation of China (No.19832020)Provincial Natural Science Foundation of Jilin (No.20000519)
文摘Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending springback of typical U-pattern is studied. At the same time the springback values of the drawing of patterns' unloading and trimming about the satellite aerial reflecting surface are predicted and also compared with those of the practical punch. Above two springbacks all obtain satisfactory results, which provide a kind of effective quantitative pre-prediction of springback for the practical engineers.
基金Supported by National Technical Innovation Foundation of China(Grant No.Jilin Province 350)
文摘Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback prediction in stretch bending forming mainly focuses on artificial neural networks combined with the finite element simulation. There is a lack of springback prediction by support vector regression(SVR). In this paper, SVR is applied to predict springback in the three-dimensional stretch bending forming process, and variable stretch force trajectory is optimized. Six parameters of variable stretch force trajectory are chosen as the input parameters of the SVR model. Sixty experiments generated by design of experiments(DOE) are carried out to train and test the SVR model. The experimental results confirm that the accuracy of the SVR model is higher than that of artificial neural networks. Based on this model, an optimization algorithm of variable stretch force trajectory using particle swarm optimization(PSO) is proposed. The springback amount is used as the objective function. Changes of local thickness are applied as the criterion of forming constraints. The objection and constraints are formulated by response surface models. The precision of response surface models is examined. Six different stretch force trajectories are employed to certify springback reduction in the optimum stretch force trajectory, which can efficiently reduce springback. This research proposes a new method of springback prediction using SVR and optimizes variable stretch force trajectory to reduce springback.
文摘This work deals with a reliability assessment of springback problem during the sheet metal forming process. The effects of operative parameters and material properties, blank holder force and plastic prestrain, on springback are in- vestigated. A generic reliability approach was developed to control springback. Subsequently, the Monte Carlo simula- tion technique in conjunction with the Latin hypercube sam- pling method was adopted to study the probabilistic spring- back. Finite element method based on implicit/explicit al- gorithms was used to model the springback problem. The proposed constitutive law for sheet metal takes into account the adaptation of plastic parameters of the hardening law for each prestrain level considered. Rackwitz-Fiessler al- gorithm is used to find reliability properties from response surfaces of chosen springback geometrical parameters. The obtained results were analyzed using a multi-state limit reli- ability functions based on geometry compensations.
文摘Springback is considered to be one of the most important problems in aluminum sheet stamp forming, leading to deviation from the designed target shape and assembly defects. In this study, a springback simulation model based on the benchmark of a Jaguar Land Rover aluminum panel is established. We embed several elastoplastic constitutive models ( Barlat' s 89, Barlat' s YLD2000, Yoshida-Uemori (YU) + Barlat' s 89, and YU + Barlat' s YLD2000) in the finite element model,in order to discuss the influence of the constitutive model selection on springback prediction in aluminum sheet forming.
文摘The forming of sheet metal in a desired and attractive shape is a process that requires an understanding of materials, mechanics and manufacturing principles. Manufacturing a consistent sheet metal component is challenging due to the nonlinear interactions of various material and process parameters. One of the major issues in the manufacturing of inconsistent?sheet metal?parts is springback. Springback is the elastic strain recovery in the material after the tooling is removed and the final shape of the product depends on the springback amount formed. In this study according to the result of simulation the inverted compensation method is adopted to optimize die surface design. Similarly, to predict and compensate the springback error this study presented an analytical approach of forming process in a stepwise modification of the automobile roof panel. Moreover, based on?Dynaform?and?finite element analysis of sheet metal stamping simulation the sprinback in automobile roof panel is predicted and compensated.?In addition, this study examines the significant requirements of the sheet metal forming precision of automobile body and the simulation of forming, stamping and springback of automobile roof panel is carried out, and the result of simulation also is analyzed.
基金Project(20050216013) supported by the Research Fund for the Doctoral Program of Higher Education
文摘Accurate springback prediction of wide sheet metal air bending process is important to improve product quality and ensure the precision in dimension. The definition of elastic limit bend angle was proposed. Based on cantilever beam elastic deforming theory, the geometrical parameters of forming tools, sheet thickness and the material yielding strain were derived and validated by the finite element method (FEM). Employing the degree of elastic limit bend angle, the equation for springback prediction was constructed, the results calculated fit well with experimental data. Especially for the small bend angle, the predicted results by equation were applied to conduct the springback prediction and compensation in industries and give closer correlation to the experimental data than those calculated by engineering theory of plastic bending.
基金The project supported by the National Natural Science Foundation of China (No. 19832020)Provincial Natural Science Foundation of Jilin China (No.20000519)
文摘The springback phenomenon of strong anisotropic sheet metals with U-channel bending as well as deep-drawing is numerically studied in detail by using Updating Lagrange FEM based on virtual work-rate principle, Kirchhoff shell element models and the Barlat-Lian planar anisotropic yield function. Simulation results are compared with a benchamark test. Very good agreement is obtained between numerical and test results. The focus of the present study is on the numerical simulation of the springback characteristics of the strong anisotropic sheet metals after unloading. The effects of the planar anisotropy coefficients and yield function exponent in the B-L yield function on the springback characteristics are discussed in detail. Some conclusions are given.
文摘A new method was worked out to improve the precision of springback prediction in sheet metal forming by combining the finite element method (FEM) with the data mining (DM) technique. First the genetic algorithm (GA) was adopted for recognizing the material parameters. Then according to the even design idea, the suitable calculation scheme was confirmed, and FEM was used for calculating the springback. The computation results were compared with experiment data, the difference between them was taken as source data, and a new pattern recognition method of DM called hierarchical optimal map recognition method (HOMR) is applied for summarizing the calculation regulation in FEM. At the end, the mathematics model of the springback simulation was established. Based on the model, the calculation errors of springback can be controlled within 10% compared with the experimental results.
文摘The objective of the present paper is to introduce a theoretical analysis of bending I-sections after pure bending. The springback values are determined to provide a quantitative method for predicting the springback using von Mises criteria. The analytical methods for the I-section are given for two cases according to the positions of the yield point along the height of the beam. The controlling parameters on the springback of I-sections are studied. The results obtained are quite successful for the prediction of springback for bending I-sections.
文摘Sheet metal single point incremental forming (SPIF) is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of the part are analysed using simple experimental method. Tool diameter, sheet thickness, step size, material parameters and the interaction of them are also analysed by using orthogonal test. The results show that the primary factor af- fecting springback is forming angle. In addition, springback is decreased when the specimen has a larger forming angle. The order of the four factors that influence springback is tool diameter, sheet thickness, step size and material parameters. The forming precision will increase if springabck is decreased by optimizing the forming parameters.
基金Project(50905008)supported by the National Natural Science Foundation of ChinaProject(2007AA041905)supported by the National High-tech Research and Development Program of ChinaProject(YWF-10-01-B08)supported by the Fundamental Research Funds for the Central Universities,China
文摘An optimization method was presented for cold stretch forming of titanium-alloy aircraft skin to determine process parameters and to reduce springback.In the optimization model,a mathematical formulation of stress difference was developed as an indicator of the degree of springback instead of implicit springback analysis.Explicit finite element method(FEM)was used to analyze the forming process and to provide the stress distribution for calculating the amount of the stress indicator.In addition,multi-island genetic algorithm(MGA)was employed to seek the optimal loading condition.A case study was performed to demonstrate the potential of the suggested method.The results show that the optimization design of process parameters effectively reduces the amount of springback and improves the part shape accuracy.It provides a guideline for controlling springback in stretch forming of aircraft skin.
文摘Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.
基金Project(50225518) supported by the National Science Foundation of China for Distinguished Young Scholars Projects(50175092 59975076) supported by the National Natural Science Foundation of ChinaProject supported by the Teaching and Research Award Program for Outstanding Young Teachers in Higher Education Institutions of MOE, PRC Project(04H53057) supported by the Aeronautical Science Foundation of China Project(Z200518) supported by the Graduate Starting Seed Fund of Northwestern Polytechnical University Project(20020699002) supported by the Specialized Research Fund for the Doctoral Program of Higher Education
文摘The springback is one of the key factors which affect the forming quality of thin-walled tube NC precision bending. The elastic-plastic finite element method was proposed to study the springback process of thin-walled tube NC precision bending and the combination of dynamic explicit algorithm and the static implicit algorithm was proposed to solve the whole process of thin-walled tube NC precision bending. Then, the 3D elastic-plastic finite element model was established based on the DYNAFORM platform, and the model was verified to be reasonable. At last, the springback rule of thin-walled tube NC precision bending and the effect of geometry and material parameters on the springback rule of thin-walled tube NC precision bending were studied, which is useful to controlling the springback of thin-walled tube NC precision bending, and the numerical simulation method can be used to study other effect of parameters on the forming quality of thin-walled tube NC precision bending.
文摘Stresses and deformation states of pipe bending are investigated under loading or unloading with various pipe materials, size, bending radius and deformation temperature. A theorem of springback of large diameter pipe bending is presented. The experiments are carried out with pipe materials of 20, 10CrMo910 and 12Cr1MoV steel. Results of computations are in good agreement with experiments.