Abstract
New materials are used in the automotive industry to reduce weight and to improve crash performance. These
materials feature a higher ratio of yield stress to elastic modulus leading to increased springback after tool release. The resulting
shape deviations and their efficient reduction is of major interest for the automotive industry nowadays. The usual strategies for
springback reduction can diminish springback to a certain amount only. In order to reduce the remaining shape deviation a
mathematical compensation algorithm is presented. The objective is to obtain the tool geometry such that the part springs back
into the right shape after releasing the tools.
In practice the process of compensation involves different tasks beginning with CAD construction of the part, planning the
drawing method and tool construction, FE-simulation, deep drawing at try-out stage and measurement of the manufactured part.
Thus the compensation can not be treated as an isolated task but as a process with various restrictions and requirements of
today’s automotive practice. For this reason a software prototype for compensation methods MASHAL – meaning program to
maintain accuracy (MASsHALtigkeit) – was developed. The basic idea of compensation with MASHAL is the transfer and
application of shape deviations between two different geometries on a third one. The developed algorithm allows for an effective
processing of these data, an approximation of springback and shape deviations and for a smooth extrapolation onto the tool
geometry.
Following topics are addressed: positioning of parts, global compensation and restriction of compensation to local areas,
damping of the compensation function in the blank holder domain, simulation and validation of springback and compensation of
CAD-data. The complete compensation procedure is illustrated on an industrial part.
Original language | Undefined |
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DOIs | |
Publication status | Published - 2005 |
Event | 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2005 - Detroit, Michigan, USA, Detroit, United States Duration: 15 Aug 2005 → 19 Aug 2005 Conference number: 6 |
Conference
Conference | 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2005 |
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Abbreviated title | NUMISHEET 2005 |
Country | United States |
City | Detroit |
Period | 15/08/05 → 19/08/05 |
Other | August 15-19, 2005 |
Keywords
- IR-76533