Abstract:
This paper presents a novel heuristic method for compensating for springback effects in metal forming processes by modifying the geometry of the forming tool. Springback, an inherent deformation that occurs when forming tools are removed, is a significant challenge, especially with high-strength steels and aluminum. Unlike previous methods that rely on complex and often difficult parameterization of the tool geometry, this new approach operates directly on the finite element description of the tool surface without requiring design parameters. The method is iterative and based on a series of forming and springback simulations using LS-DYNA. After each simulation cycle, the difference between the resulting part geometry and the desired final shape is calculated. This deviation is then mapped back to the tool surface, which is modified in the opposite direction of the springback displacement to compensate for the deformation. A smoothing function is applied to ensure the modification is smooth and robust. The methodology is demonstrated on a doubly curved sheet, showing fast convergence to the desired shape after just a few iterations. The author highlights that this approach is considerably faster than optimization-based techniques and is applicable to a wide variety of shapes and materials, offering a practical solution for industries where tight tolerances are critical.
