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Shape error compensation in flexible forming process using overbending surface method

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Abstract

In this article, the design of the flexible forming process considering die shape compensation using an iterative overbending method based on numerical simulation is carried out. In this method, the springback shape obtained from the final step of the first forming simulation is compared with the desired objective shape, and the shape error is calculated as a vector norm with three-dimensional coordinates. The error vector is inversely added to the objective surface to compensate both the upper and lower flexible die configuration. The flexible dies are made up of several punches that make a forming die that is equivalent to a solid die, thus the forming surface shape can be reconfigurable with regard to the compensated die shapes. The flexible die shapes are recalculated, and the punch arrays are adjusted according to the overbent forming surface. These iterative procedures are repeated until the shape error variation converges. In addition, experimental verification is carried out using a 2,000-kN flexible forming apparatus for thick plates. Finally, the configuration of the prototype obtained from the experiment is compared with the numerical simulation results, which have consideration of the springback compensation. Consequently, it is confirmed that the suggested method for compensating the forming error could be used in the design of the flexible forming process for thick-curved plates.

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Authors and Affiliations

  1. Department of Aerospace Engineering, Pusan National University, Busan, 609-735, South Korea

    Seong-Chan Heo, Jae-Nam Kim & Beom-Soo Kang

  2. Industrial Liaison Innovation Center, Pusan National University, Busan, 609-735, South Korea

    Woo-Jin Song & Tae-Wan Ku

Authors
  1. Seong-Chan Heo
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  2. Jae-Nam Kim
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  3. Woo-Jin Song
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  4. Tae-Wan Ku
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  5. Beom-Soo Kang
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Correspondence to Beom-Soo Kang.

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Heo, SC., Kim, JN., Song, WJ. et al. Shape error compensation in flexible forming process using overbending surface method. Int J Adv Manuf Technol 59, 915–928 (2012). https://doi.org/10.1007/s00170-011-3562-5

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  • DOI: https://doi.org/10.1007/s00170-011-3562-5

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