New approaches for springback-based offline dimensional control in sheet metal forming

Abstract

The springback reduction is a difficult task and the subject of numerous research studies in the field of sheet metal forming. In this paper, we develop a new integrated-optimal dimensional offline control approach for springback and a new approach for springback reduction. The key idea is to build a reduced-order model of the entire blank-process-tooling system and, by using it, to find the optimal values of the system parameters for which the part accuracy and precision are the highest using a searching algorithm. The integrated-optimal dimensional offline control of springback consists in three modules simulation, reduced-order modelling and optimization. FEM is used for simulation. NN modelling is used for building the reduced-order modelling. For optimization, the searching algorithm is used. Using the exhaustive search the part accuracy and precision are evaluated by considering the system parameters values as belonging to their tolerated domains of variation. The approach implementation is applied to sheet multipoint forming with interpolators. Finally, the results come to validate the integrated-optimal dimensional offline control of springback approach and for the new optimized springback reduction, the obtained accuracies and precisions are presented.