An Optimization Procedure for Springback Compensation using LS-OPT

Abstract: 

This paper develops a fully‑parametric shape‑optimization workflow for compensating springback in sheet‑metal stamping, integrating TrueGrid® for geometric parameterization, LS‑DYNA for explicit dynamic springback simulation, and LS‑OPT’s successive response‑surface optimization . Nine design variables — including corner radii and eight flange control‑point offsets — are defined to alter die geometry within bounded limits. A minimax formulation minimizes the maximum perpendicular offset of 24 flange points relative to a best‑fit plane after springback. Iterative experimental designs of 16 parallel LS‑DYNA runs per iteration converge in five iterations (≈18 h wall‑clock time) on a 16‑CPU server, reducing maximum flange warp from 3.2 mm to 0.8 mm on the NUMISHEET’96 S‑Rail benchmark. Results demonstrate consistent springback trends with die shape changes and validate a robust, simulation‑driven parametric optimization strategy that drastically reduces trial‑and‑error tooling time and cost.

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