Abstract
A precise production of sheet metal parts has always been a main goal in press shops. Highest quality demands are required especially in automotive production. Unfortunately, even today, the production is not optimal due to an ineffective approach to the springback compensation. Springback results in geometrical shape inaccuracies of the obtained product. Based on the current approach, excessive time and financial costs emerge due to corrections on the press tools. However, these corrections do not always lead to a better accuracy of the stampings. The main objective of the research is to design a modified solution of the current approach. The modified solution is designed as a methodology with a focus on the analysis and compensation of the springback with a help of a numerical simulation. To achieve the main goal, smaller sub-goals are employed. These sub-goals, or rather experiments, mainly focus on parameters, which, more or less, influence the springback phenomenon. The designed methodology is verified with real car body parts and is carried out with a help of the department of the press tools design in ŠKODA AUTO, a.s. There, the methodology is used for improving the accuracy of the stamping process of the car body parts and for improving the quality of the final product.
Highlights
At the final stage of forming, as soon as the load is removed and stamping tools released, the product springs out
Springback is a significant problem in the process of sheet metal forming, since it results in geometrical shape inaccuracies of the final product
In terms of bending operations, springback has already been described by many authors
Summary
At the final stage of forming, as soon as the load is removed and stamping tools released, the product springs out. This is caused by internal stresses (elastic deformation). Springback is a significant problem in the process of sheet metal forming, since it results in geometrical shape inaccuracies of the final product. That includes intervention into the tools geometry in the form of corrections This leads to an increase in the costs of the whole project. Springback should be solved in the pre-production stage of the project. In this stage, various numerical simulations and special computational modules can be used. If the experimental trial and error process is replaced by a reliable numerical procedure, the pre-production time and costs can be decreased significantly. [2,3,4]
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