02 AdvancedSpringbackSeminar Principles

The Advanced Springback Seminar
The Principles

Springback Compensation The Principles
Chennai, India, July 9th, 2010
Version 1.1
Current challenges
Physical tool geometry correction loops are timetime- and
cost--intensive
cost
Simulation--based springback compensation eliminates
Simulation
compensation loops
Start
Simulation
based tryout
Accurate simulation
of springback
Part geometry
Springback result
Physical tryout
Effective compensation
of active surfaces
2

Version 1.1
Springback Compensation is State-of-the-Art

Confirmed by numerous practical examples:
Accurate Springback
Simulation
Effective Compensation
of the Active Surfaces
Your achivable savings in the Tool Shop:

Halve your trytry-out loops
Significant reduction of your lead time
3

Project Roof reinforcement

Before springback compensation
2.0 mm
0.8 mm
After springback compensation
0.4 mm
0.05 mm
(green: part geometry; red: sheet after springback)
Project Spare wheel tray

Before springback compensation
0.8 mm
1.1 mm
After springback compensation
0.1 mm
0.2 mm
(green: part geometry; red: sheet after springback)

Version 1.1
Advanced Springback Compensation - Workflow

The principals of Advanced Springback Compensation will be

illustrated on two examples
Cross Member Under Body
Tunnel

Version 1.1
Principle 1: Proper Basic Simulation

Development of an optimal forming process using AutoForm
Process layout, concept, draw die geometry
Consideration of all OP
OPs, optimal Process parameter
Clamping conditions of measuring device
Part must met the final quality demands before an accurate

springback simulation will be executed.
Free of splits
Free of wrinkles
Final blank shape

Version 1.1
Principle 2: Springback simulation requires special settings
AutoForm developed Final Validation Settings for a fast and

accurate springback result
Checklist: Final Validation
- Elastic Plastic Shell
- Standard
Standard--settings plus:
- Initial element size
size::
2 * min. DieDie-radius (max
(max.. 20 mm)
- Max refinement level
level:: 5
- Max element angle: 22.5
22.5
- EndTimeStep
EndTimeStep:: 0.4
-

Version 1.1
Example 1: Cross Member Under Body

Part from Numisheet 2005
Material and thickness
DP600 (1.62 mm)
Binder Travel
100 mm
Binder Force
1068 KN (appr
(appr.. 110 ton)
10

Version 1.1
Forming of Cross Member Under Body

First Operation: Drawing
Second Operation: Cutting
Finally,, Springback
Finally
11

Version 1.1
Evaluation on Principle 1
Critical wrinkling tendency determined, must be solved in
simulation first.
Wrinkling tendency has been confirmed by experiments at the Numisheet 2005 benchmark
12

Version 1.1
Process optimization
Several measures have been taken to improve the drawing
process in order to meet the required quality demands
Introduction of sharp radius and
vertical wall at open end to hold
and control material flow
Introduction of depression for

material consumption to reduce
wrinkles
Adjustment of drawbead restraining forces and blankholder force to

further optimize the drawing process
13

Version 1.1
Evaluation on Principle 1 of optimized process

A result evaluation must be executed
Splits & wrinkles
But also on required forces & blank shape
The wrinkling tendency has been reduced significantly
Old process
Optimized process
Wrinkling criterion
14

Version 1.1
Principle 3: Evaluate Springback in a defined way

Springback result must be evaluated in a well defined and repeatable
way
AutoForm recommends
constrained springback with:
Minimum clamping concept
Clamping concept as close as
possible to future real clamping
concept
5.03
3.68
15
Version 1.1
Principle 4: Ensure the process is stable

(Springback
Springback)) Results vary in reality due to scatter of all kind of
parameters like material variation, friction, forces etc..
This variation not only turns up at production but at tool trytry-out as well
Input
Output
(Yield stress,
MPa))
MPa
307
(Springback,
mm)
Forming
process
323
338
1.0
4.3
8.7
How much must the tool be compensated?

Compensation doesnt guarantee success
AutoForm developed an inputinput-set for AutoForm
AutoForm--Sigma in order to
properly represent the real life result variation
It is strongly recommended to assure that your process is stable by
using AutoFormAutoForm-Sigma. Compensation is only reasonable with a
robust springback
16
Version 1.1
Evaluation on Principle 4
Process stable with respect to springback?
springback?
Variation of inputinput-parameters:
Sheet thickness
R-values 0
0, 45
45 and 90
90
Yield stress and tensile strength
Binder force
Friction
Evaluation of Process Capability Cp

Cp indicates whether the results remain
within a defined width
If only green and yellow: stable
The Under Body Cross Member is ready for compensation

17

Version 1.1
Springback Compensation
Starting point
Tool surface (red) is identical to part geometry (white)
Springback simulation
Springback(x mm)
Springback Compensation Loop

Springback results are extracted from tool surface
Compensation
(x mm)
Compensation
(x mm)
Compensation
(x mm)
Compensation
(x mm)
Springback (y mm)
Springback simulation based on new tool geometry

18

Version 1.1
Springback Compensation
Using the Predefine compensation regions,
regions, the areas for the
compensation are determined automatically.
Part: The original part data are compensated according to the springback results by
Part:
the factor 1 (Direct).
(Direct).
Binder:: The defined binder is fixed (Fixed
Binder
(Fixed).
).
Fill and Addendum define the transition area (Transition).
Manually definition possible like Open End Wall Angle which must remain
perpendicular to binder (Fixed)
19

Version 1.1
Principle 5: Compensation just does

The compensation just takes the available springback result to
extract the tool geometry, no further interpretation or evaluation has
been done
First compensation loop
Straight forward compensation gives swinging of the blankholder
Manual manipulation necessary
20

Version 1.1
Smooth binder surface

Straight forward compensation gives some swinging of the
blankholder
Manual manipulation required, several approaches possible e.g.
use morphing functionality in Geometry generator
define blankholder as compensation region: fixed draft
Blankholder looks smooth now
21

Version 1.1
Shape deviation after compensation

Compensation loop 1
Before compensation
The max. shape

deviation is 7.3 mm
The max. shape

deviation is 0.92 mm
Final compensation loop
Desired part(turquoise)
Sheet after springback (blue)
Compensated tool (red)
The max. shape deviation

is well-controlled under
0.32mm, which is inside
given tolerance.
22

Version 1.1
Example 2: Tunnel
Part from AutoForm
Material and thickness
CR180A (1.00 mm)
Binder Travel
174 mm
Binder Force
6000 KN (appr
(appr.. 600 ton)
23

Version 1.1
Forming of Tunnel
First Operation: Drawing
Second & Third Operation: Forming & Cutting
Finally,, Springback
Finally
24

Version 1.1
Evaluation
Principle 1: a proper basic simulation
Principle 2: In order to execute a springback simulation Final
Validation Settings are required
Principle 3: Evaluate springback in a well defined and repeatable
way
Waviness occurs, typical effect of straight walls with local stiffeners
Lets compensate!
Wavy
25

Version 1.1
Sprinback compensation
Compensation shows alternating results of the wavy wall
Before compensation
Compensation loop 1
Compensation loop 2
Compensation loop 3
26

Version 1.1
Evaluation on Principle 4: Ensure the process is stable

The alternating result of the wavy wall correspond to the
unstable area
Again a proof that it doesnt make sense to compensate
unstable processes
Before compensation
Compensation loop 1
27

Version 1.1
Springback compensation
Two major options to continue with this part:
Modify part geometry in order to get rid of waviness
Accept waviness, keep wall of the tool straight and compensate
Strongly recommend to discuss

discuss either option with your
customer
28

Version 1.1
Potential in Part Design

Part
Designer
Feasibility
Process
Planning
Part design with minimal

springback in mind
Beads, Embossments
Steps
Material specification

Tool
Design
Tool
Production
Tryout
Lessons learned from the Tunnel

Springback is a feasibility criterion
The forming process has to be
optimized until the part meets the
final quality demands (Principle 1)
Compensation is not reasonable
without a robust springback
(Principle 4)
29
Project Longitudinal
Springback simulation achieves that good results that
its productive application has unquestionable been accepted
30

Because of the high strength material with a 340 MPa yield stress, Daimler
classified this part as risky
Noteworthy is the fact that three OPs have been compensated not only one
AutoForm-Compensator and AutoFormAutoFormAutoForm-Sigma have been used, for the
simulation AutoForm Final Validation settings have applied
31

Major achievements:
Dimensionally stable parts could be pressed after two instead of four
correction loops
Moreover, a time saving of eight weeks could be achieved
32


Principle 1: You require a proper basic simulation
Principle 2: In order to execute a springback simulation
Final Validation Settings are required
Principle 3: Evaluate springback in a well defined and
repeatable way
Principle 4: Ensure the process is stable
Principle 5: Compensation just does; it doesnt
interpret or evaluate
33

Version 1.1
Influence on your Working-Process

Present Procedure:
Tryout samples have been measured
A compensation strategy is determined
Generally the process engineer is not involved
Feasibility
Process
Planning
Tool
Design
Tool
Production
Tryout
Future Procedure:
The process engineer develops a compensation
strategy at an early stage
The necessary springback and compensation
know--how has been developed
know
The active surfaces are already compensated
in the engineering department.
34

Version 1.1
Summary and Perspective

Springback simulations can reliably be performed with
AutoForm Final Validation settings
Springback compensation can productively be applied using
AutoForm
Compensation strategies can be complex
Springback simulation and springback compensation require
additional expertise of the user
AutoForm offers you support

for the implementation of
this leading edge technology
35


02 AdvancedSpringbackSeminar Principles

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02 AdvancedSpringbackSeminar Principles

Încărcat de

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Formate disponibile

The Advanced Springback Seminar

The Advanced Springback Seminar

The Advanced Springback Seminar

Springback Compensation is State-of-the-Art

Your achivable savings in the Tool Shop:

The Advanced Springback Seminar

Project Roof reinforcement

Project Spare wheel tray

After springback compensation

(green: part geometry; red: sheet after springback)

Advanced Springback Compensation - Workflow

The Advanced Springback Seminar

The principals of Advanced Springback Compensation will be

The Advanced Springback Seminar

Principle 1: Proper Basic Simulation

Part must met the final quality demands before an accurate

The Advanced Springback Seminar

Principle 2: Springback simulation requires special settings

AutoForm developed Final Validation Settings for a fast and

The Advanced Springback Seminar

Example 1: Cross Member Under Body

The Advanced Springback Seminar

Forming of Cross Member Under Body

Second Operation: Cutting

The Advanced Springback Seminar

The Advanced Springback Seminar

Introduction of depression for

Adjustment of drawbead restraining forces and blankholder force to

The Advanced Springback Seminar

Evaluation on Principle 1 of optimized process

The Advanced Springback Seminar

Principle 3: Evaluate Springback in a defined way

Principle 4: Ensure the process is stable

How much must the tool be compensated?

Evaluation of Process Capability Cp

The Under Body Cross Member is ready for compensation

The Advanced Springback Seminar

Springback Compensation Loop

Springback simulation based on new tool geometry

The Advanced Springback Seminar

The Advanced Springback Seminar

Principle 5: Compensation just does

The Advanced Springback Seminar

Smooth binder surface

The Advanced Springback Seminar

Shape deviation after compensation

The max. shape

The max. shape

The max. shape deviation

The Advanced Springback Seminar

The Advanced Springback Seminar

Second & Third Operation: Forming & Cutting

The Advanced Springback Seminar

The Advanced Springback Seminar

The Advanced Springback Seminar

Evaluation on Principle 4: Ensure the process is stable

The Advanced Springback Seminar

Strongly recommend to discuss

The Advanced Springback Seminar

Potential in Part Design

Part design with minimal

The Advanced Springback Seminar

Lessons learned from the Tunnel