An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application
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摘要
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.
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.
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.
引文
[1]G Wei,R H Wagoner.Die design method for sheet springback.International Journal of Mechanical Sciences,2004,46(7):1097-1113.
[2]R Rufni,J Cao.Using neural network for springback minimization in a channel forming process.Journal of Material Process Technology,2010,1:77-85.
[3]Z M Fu,J H Mo,F Han,et al.Tool path correction algorithm for single-point incremental forming of sheet metal.International Journal of Advanced Manufacturing Technology,2013,64(9):1239-1248.
[4]J Zhao,R X Zhai,Z P Qian,et al.A study on spring back of profle plane stretch-bending in the loading method of pretension and moment.International Journal of Mechanical Sciences,2013,75:45-54.
[5]Z W Gu,M W Lv,X Li,et al.Stretch bending defects control of L-section aluminum components with variable curvatures.International Journal of Advanced Manufacturing Technology,2016,85(5):1053-1061.
[6]R X Zhai,X H Ding,S M Yu,et al.Stretch bending and springback of profle in the loading method of prebending and tension.International Journal of Mechanical Sciences,2018,144:746-764.
[7]R K Verma,K Chung,T Kuwabara.Efect of pre-strain on anisotropic hardening and springback behavior of an ultra low carbon automotive steel.ISIJInternational,2011,51(3):482-490.
[8]B Chongthairungruang,V Uthaisangsuk,S Suranuntchai,et al.Experimental and numerical investigation of springback efect for advanced high strength dual phase steel.Material Design,2012,39:318-328.
[9]L F Wang,G H Huang,H Zhang,et al.Evolution of springback and neutral layer of AZ31B magnesium alloy V-bending under warm forming conditions.Journal of Material Process Technology,2013,213(6):844-850.
[10]Y Y Zong,P Liu,B Guo,et al.Springback evaluation in hot v-bending of Ti-6Al-4V alloy sheets.International Journal of Advanced Manufacturing Technology,2015,76(1):577-585.
[11]W L Edwards,T J Grimm,I Ragai,et al.Optimum process parameters for springback reduction of single point incrementally formed polycarbonate.Procedia Manufacturing,2017,10:329-338.
[12]A P Karafllis,M C Boyce.Tooling design in sheet metal forming using springback calculations.International Journal of Mechanical Sciences,1992,34(2):113-131.
[13]A P Karafllis,M C Boyce.Tooling and binder design for sheet metal forming processes compensating springback error.International Journal of Machine Tools&Manufacture,1996,36(4):503-526.
[14]R Lingbeek,J Huetink,S Ohnimus,et al.The development of a fnite elements based on springback compensation tool for sheet metal products.Journal of Material Process Technology,2005,169(1):115-125.
[15]H S Cheng,J Cao.An accelerated springback compensation method.International Journal of Mechanical Sciences,2007,49(3):267-279.
[16]X A Yang,F Ruan.A die design method for springback compensation based on displacement adjustment.International Journal of Mechanical Sciences,2011,53(5):399-406.
[17]G Cafuta,N Mole,B?tok.An enhanced displacement adjustment method:springback and thinning compensation.Material Design,2012,40:476-487.
[18]W A Siswanto,A D Anggono,B Omar,et al.An alternate method to springback compensation for sheet metal forming.The Scientifc World Journal,2014:301271.
[19]J Liao,X Xue,C Zhou,et al.A springback compensation strategy and applications to bending cases.Steel Research International,2013,84(5):463-472.
[20]Z K Zhang,J J Wu,S Zhang,et al.A new iterative method for springback control based on theory analysis and displacement adjustment.International Journal of Mechanical Sciences,2015,105:330-339.
[21]I N Vladimirov,M P Pietryga,S Reese.Prediction of springback in sheet forming by a new fnite strain model with nonlinear kinematic and isotropic hardening.Journal of Material Process Technology,2009,209(8):4062-4075.
[22]X Q Peng,S Q Shi,K K Hu.Comparison of material models for spring back prediction in an automotive panel using fnite element method.Journal of Materials Engineering and Performance,2013,22(10):2990-2996.
[23]A Maia,E Ferreira,M C Oliveira,et al.3-Numerical optimization strategies for springback compensation in sheet metal forming.Computational Methods&Production Engineering,2017:51-82.
[24]I Gil,E Mugarra,J Agirre,et al.Influence of material and tribological modelling on the prediction of big size automotive components springback.Key Engineering Materials,2016,716:713-718.
[25]F M Brand?o,S Delijaicov,Bortolussi R.CAF-a simplifed approach to calculate springback in Al 7050 alloys.International Journal of Advanced Manufacturing Technology,2017,91(9):1-12.
[26][26]D M Neto,M C Oliveira,A D Santos,et al.Influence of boundary conditions on the prediction of springback and wrinkling in sheet metal forming.International Journal of Mechanical Sciences,2017,122:244-254.
[27]G Y Gao,G C Yu,J Zhao,et al.Rolling round process of four-roll and its springback analysis.Journal of Plasticity Engineering,2017,24(1):55-62.
[28]N Saito,M Fukahori,D Hisano,et al.Efect of stress relaxation on springback of steel sheet in warm forming.Key Engineering Materials,2017,725:671-676.
[29]C G Wang,G C Yu,W Wang,et al.Deflection detection and curve ftting in three-roll continuous straightening process for LSAW pipes.Journal of Materials Processing Technology,2018,255:150-160.
[30]Y X Wang.Forging and stamping technology.Beijing:Metallurgical Industry Press,1994.
[31]Y B Zhong.Stamping process and die design.Beij Jing:Machinery Industry Press,2000.
[32]J Zhao,J Yin,R Ma,et al.Springback equation of small curvature plane bending.Science China Technological Sciences,2011,54:2386-2396.
[2]R Rufni,J Cao.Using neural network for springback minimization in a channel forming process.Journal of Material Process Technology,2010,1:77-85.
[3]Z M Fu,J H Mo,F Han,et al.Tool path correction algorithm for single-point incremental forming of sheet metal.International Journal of Advanced Manufacturing Technology,2013,64(9):1239-1248.
[4]J Zhao,R X Zhai,Z P Qian,et al.A study on spring back of profle plane stretch-bending in the loading method of pretension and moment.International Journal of Mechanical Sciences,2013,75:45-54.
[5]Z W Gu,M W Lv,X Li,et al.Stretch bending defects control of L-section aluminum components with variable curvatures.International Journal of Advanced Manufacturing Technology,2016,85(5):1053-1061.
[6]R X Zhai,X H Ding,S M Yu,et al.Stretch bending and springback of profle in the loading method of prebending and tension.International Journal of Mechanical Sciences,2018,144:746-764.
[7]R K Verma,K Chung,T Kuwabara.Efect of pre-strain on anisotropic hardening and springback behavior of an ultra low carbon automotive steel.ISIJInternational,2011,51(3):482-490.
[8]B Chongthairungruang,V Uthaisangsuk,S Suranuntchai,et al.Experimental and numerical investigation of springback efect for advanced high strength dual phase steel.Material Design,2012,39:318-328.
[9]L F Wang,G H Huang,H Zhang,et al.Evolution of springback and neutral layer of AZ31B magnesium alloy V-bending under warm forming conditions.Journal of Material Process Technology,2013,213(6):844-850.
[10]Y Y Zong,P Liu,B Guo,et al.Springback evaluation in hot v-bending of Ti-6Al-4V alloy sheets.International Journal of Advanced Manufacturing Technology,2015,76(1):577-585.
[11]W L Edwards,T J Grimm,I Ragai,et al.Optimum process parameters for springback reduction of single point incrementally formed polycarbonate.Procedia Manufacturing,2017,10:329-338.
[12]A P Karafllis,M C Boyce.Tooling design in sheet metal forming using springback calculations.International Journal of Mechanical Sciences,1992,34(2):113-131.
[13]A P Karafllis,M C Boyce.Tooling and binder design for sheet metal forming processes compensating springback error.International Journal of Machine Tools&Manufacture,1996,36(4):503-526.
[14]R Lingbeek,J Huetink,S Ohnimus,et al.The development of a fnite elements based on springback compensation tool for sheet metal products.Journal of Material Process Technology,2005,169(1):115-125.
[15]H S Cheng,J Cao.An accelerated springback compensation method.International Journal of Mechanical Sciences,2007,49(3):267-279.
[16]X A Yang,F Ruan.A die design method for springback compensation based on displacement adjustment.International Journal of Mechanical Sciences,2011,53(5):399-406.
[17]G Cafuta,N Mole,B?tok.An enhanced displacement adjustment method:springback and thinning compensation.Material Design,2012,40:476-487.
[18]W A Siswanto,A D Anggono,B Omar,et al.An alternate method to springback compensation for sheet metal forming.The Scientifc World Journal,2014:301271.
[19]J Liao,X Xue,C Zhou,et al.A springback compensation strategy and applications to bending cases.Steel Research International,2013,84(5):463-472.
[20]Z K Zhang,J J Wu,S Zhang,et al.A new iterative method for springback control based on theory analysis and displacement adjustment.International Journal of Mechanical Sciences,2015,105:330-339.
[21]I N Vladimirov,M P Pietryga,S Reese.Prediction of springback in sheet forming by a new fnite strain model with nonlinear kinematic and isotropic hardening.Journal of Material Process Technology,2009,209(8):4062-4075.
[22]X Q Peng,S Q Shi,K K Hu.Comparison of material models for spring back prediction in an automotive panel using fnite element method.Journal of Materials Engineering and Performance,2013,22(10):2990-2996.
[23]A Maia,E Ferreira,M C Oliveira,et al.3-Numerical optimization strategies for springback compensation in sheet metal forming.Computational Methods&Production Engineering,2017:51-82.
[24]I Gil,E Mugarra,J Agirre,et al.Influence of material and tribological modelling on the prediction of big size automotive components springback.Key Engineering Materials,2016,716:713-718.
[25]F M Brand?o,S Delijaicov,Bortolussi R.CAF-a simplifed approach to calculate springback in Al 7050 alloys.International Journal of Advanced Manufacturing Technology,2017,91(9):1-12.
[26][26]D M Neto,M C Oliveira,A D Santos,et al.Influence of boundary conditions on the prediction of springback and wrinkling in sheet metal forming.International Journal of Mechanical Sciences,2017,122:244-254.
[27]G Y Gao,G C Yu,J Zhao,et al.Rolling round process of four-roll and its springback analysis.Journal of Plasticity Engineering,2017,24(1):55-62.
[28]N Saito,M Fukahori,D Hisano,et al.Efect of stress relaxation on springback of steel sheet in warm forming.Key Engineering Materials,2017,725:671-676.
[29]C G Wang,G C Yu,W Wang,et al.Deflection detection and curve ftting in three-roll continuous straightening process for LSAW pipes.Journal of Materials Processing Technology,2018,255:150-160.
[30]Y X Wang.Forging and stamping technology.Beijing:Metallurgical Industry Press,1994.
[31]Y B Zhong.Stamping process and die design.Beij Jing:Machinery Industry Press,2000.
[32]J Zhao,J Yin,R Ma,et al.Springback equation of small curvature plane bending.Science China Technological Sciences,2011,54:2386-2396.