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An accelerated springback compensation method for creep age forming

Abstract

Springback compensation is essential for tool design in creep age forming (CAF) process. In this study, a new accelerated springback compensation method integrating springback mechanism of a plate with creep-ageing behaviour of materials has been developed for CAF tool design to manufacture both singly and varyingly curved products. Springback compensation curves that relate the objective shapes and springback compensated shapes by their curvature, stress and strain states have been established, based on the numerical solution of springback behaviour of CAF process. For singly curved products, a one-step springback compensation method is proposed with reference to the springback compensation curves, and its effectiveness has been demonstrated by CAF test with a peak-aged aluminium alloy AA6082-T6. For products with varying curvatures, an accelerated method is developed for CAF tool design by integrating springback compensation curves with finite element (FE) assisted displacement adjustment techniques. The new accelerated method can significantly improve the tool design efficiency for CAF process when compared with conventional displacement adjustment techniques and has been verified by CAF manufacture of a varyingly curved product with AA6082-T6 material. The new accelerated springback compensation method developed in this study can be used for efficient tool design for CAF process of various products.

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Acknowledgements

The research was performed at the CRRC Sifang-Imperial Centre for Rail Transportation Manufacturing Technologies at Imperial College London. The authors would like to thank Mr. Suresh Viswanathan for his technical help in carrying out CAF tests.

Funding

This work was supported by CRRC Qingdao Sifang Co., Ltd.

Author information

Correspondence to Zhusheng Shi.

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Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

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Cite this article

Li, Y., Rong, Q., Shi, Z. et al. An accelerated springback compensation method for creep age forming. Int J Adv Manuf Technol 102, 121–134 (2019). https://doi.org/10.1007/s00170-018-3175-3

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Keywords

  • Creep age forming
  • Springback compensation
  • Displacement adjustment
  • Tool design
  • Stress-relaxation
  • AA6082-T6