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Compensate for longitudinally discrepant springback and bow in chain-die forming processes by multiple sections optimization

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Abstract

As a gradual deformation process like roll forming, chain-die forming is attractive to manufacturing advanced high-strength steel (AHSS) channels. The gradual forming mode induces complex and longitudinally discrepant springback and brings additional difficulty to the die design of AHSS forming. In this work, a new chain-die design method by adopting a multi-cross-section compensation strategy is proposed to compensate for the longitudinally discrepant springback and bow. A hat geometry with six design variables is adopted to ensure an undercut-free and smooth optimized die surface. The sectional springback compensation is taken as a multi-objective optimization problem, and the non-dominated sorting genetic algorithm-II is used to minimize the deviation between calculated sectional springback profiles and desired geometry. In addition, the longitudinal bow is also taken into account with an optimal counterpart arc on the web. The optimal results indicate that the non-uniform springback in chain-die forming exhibits a linear variation along the longitudinal direction for the constant hat channel. Chain-die forming experiments of constant and variable AHSS channels are carried out for verification, and both the springback and longitudinal bow are reduced by using the proposed die design method.

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Acknowledgements

The authors would like to acknowledge the support of the National Natural Science Foundation of China (Grant No. U1860110). The experimental materials and facilities provided by Baosteel Research Institute and Ningbo SaiRolf Metal Forming Co., Ltd. are also acknowledged.

Funding

This research was funded by the National Natural Science Foundation of China (Grant No. U1860110).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, China

    Zhenye Liang, Tianxia Zou, Wei Dai, Zhiheng Zhang, Yang Liu, Kaijun Lu, Dayong Li & Yinghong Peng

  2. School of Mechanical and Mining Engineering, The University of Queensland, St Lucia, Brisbane, QLD, 4072, Australia

    Shichao Ding

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  1. Zhenye Liang
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  2. Tianxia Zou
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  3. Wei Dai
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Contributions

Zhenye Liang: conceptualization, methodology, simulation, experiments, writing—original draft; Tianxia Zou: resources, funding acquisition, conceptualization, methodology, writing - review and editing; Wei Dai: programming, validation; Zhiheng Zhang: experiments, validation; Yang Liu: experiments, validation; Kaijun Lu: simulation, validation; Dayong Li: resources, funding acquisition, conceptualization, writing - review and editing, supervision; Shichao Ding: conceptualization, methodology; Yinghong Peng: resources, project administration.

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Correspondence to Tianxia Zou or Dayong Li.

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Appendix

Appendix

Table 11 lists the sample points and the calculated displacement fields of the chain-die formed constant hat channel. Note that only the displacement fields of the lead section are presented. Table 12 lists the initial sample points and the calculated displacement fields of the variable hat channel, and only the displacement fields of the lead section are presented.

Table 11 The calculated springback results of 60 initial sample points for the chain-die formed constant hat channel
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Table 12 The calculated springback results of the sample points for the chain-die formed variable hat channel
Full size table

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Liang, Z., Zou, T., Dai, W. et al. Compensate for longitudinally discrepant springback and bow in chain-die forming processes by multiple sections optimization. Int J Adv Manuf Technol 121, 6407–6430 (2022). https://doi.org/10.1007/s00170-022-09728-6

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