An accelerated springback compensation method

Part shape error due to springback is usually considered to be a manufacturing defect in sheet metal forming process. This problem can be corrected by adjusting the tooling shape to the appropriate shape and/or active process control. In this paper, the focus will be on tooling shape design. The traditional trial-and-error methods are inefficient for complex dies. Several analytical methods have been proposed in recent years. Each of these has their advantages and disadvantages. As expected, all these methods required a few iteration steps before converting to the desired tooling shape. Here, we put all of these proposed methods under the same framework. Additionally, built upon existing methods, a new methodology is proposed by incorporating pure geometry correction with fundamental mechanics analysis. Consequently, the convergence becomes much faster and certain. Tooling design results from the new method, together with three existing methods, are compared with each other and an experiment.