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A Numerical Approach for Predicting the Springback of Intersecting High-Stiffened Integral Panel in Spherical Die Forming

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Abstract

Taking advantage of the high specific strength, structural efficiency, and rigidity of spherical multi-intersecting high-stiffened integral panels, they have been used on a manned space station as the main load-bearing structure. Due to their large size and complex structure, a new incremental die forming approach was proposed, where the panel is pressed by a relatively small die at devised positions multiple times in proper order. However, the springback behavior of the panel after each depression is extremely complicated due to the interactions between multi-intersecting ribs. In this paper, a numerical approach of springback prediction for a typical intersecting stiffened panel in spherical die forming was proposed and the corresponding algorithm was developed. The approach quantifies the influence between multi-intersecting ribs by a novel definition of a bending neutral layer on the panel: the 3-D springback of whole panel is equivalent to the 2-D springback of the ribs. The strain component led by skin deformation and its elastic release are considered. A plasticity model with a nonlinear strain hardening of material was adopted. The approach was employed to predict the springback of panels with different forming radii, different rib sizes, and local large-rigidity structures. A rapid springback compensation based on the approach was achieved. The calculated results are in strong agreement with the results of FEM simulations based on ABAQUS software and experiments, accurately predicting profiles error within 2 mm.

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Acknowledgements

The authors would like to acknowledge the funding support to this research by the project of No. U1737101 from the National Natural Science Foundation of China

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China

    Qiyuan He, Weidong Li, Min Wan & Cailing Li

  2. Beijing Space Craft, China Academy of Space Technology, Beijing, 100094, China

    Chao Cui

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  1. Qiyuan He
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  2. Weidong Li
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  3. Min Wan
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  4. Cailing Li
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  5. Chao Cui
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Correspondence to Weidong Li.

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The custom codes are available from the corresponding author on reasonable request.

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He, Q., Li, W., Wan, M. et al. A Numerical Approach for Predicting the Springback of Intersecting High-Stiffened Integral Panel in Spherical Die Forming. Int. J. Precis. Eng. Manuf. 23, 593–608 (2022). https://doi.org/10.1007/s12541-022-00642-1

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  • DOI: https://doi.org/10.1007/s12541-022-00642-1

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