Characterising material and process variation effects on springback robustness for a semi-cylindrical sheet metal forming process

de Souza, Timothy and Rolfe, Bernard F. 2010, Characterising material and process variation effects on springback robustness for a semi-cylindrical sheet metal forming process, International journal of mechanical sciences, vol. 52, no. 12, pp. 1756-1766.

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Title Characterising material and process variation effects on springback robustness for a semi-cylindrical sheet metal forming process
Author(s) de Souza, Timothy
Rolfe, Bernard F.
Journal name International journal of mechanical sciences
Volume number 52
Issue number 12
Start page 1756
End page 1766
Total pages 11
Publisher Elsevier
Place of publication Amsterdam, The Netherlands
Publication date 2010
ISSN 0020-7403
1879-2162
Keyword(s) springback
sheet metal forming
stochastic modelling
robustness
Summary Variation in the incoming sheet material and fluctuations in the press setup is unavoidable in many stamping plants. The effect of these variations can have a large influence on the quality of the final stamping, in particular, unpredictable springback of the sheet when the tooling is removed. While stochastic simulation techniques have been developed to simulate this problem, there has been little research that connects the influence of the noise sources to springback. This paper characterises the effect of material and process variation on the robustness of springback for a semi-cylindrical channel forming operation, which shares a similar cross-section profile as many automotive structural components. The study was conducted using the specialised sheet metal forming package AutoFormTM Sigma, for which a series of stochastic simulations were performed with each of the noise sources incrementally introduced. The effective stress and effective strain scatter in a critical location of the part was examined and a response window, which indicates the respective process robustness, was defined. The incremental introduction of the noise sources allows the change in size of the stressstrain response window to be tracked. The results showed that changes to process variation parameters, such as BHP and friction coefficient, directly affect the strain component of the stressstrain response window by altering the magnitude of external work applied to forming system. Material variation, on the other hand, directly affected the stress component of the response window. A relationship between the effective stressstrain response window and the variation in springback was also established.
Language eng
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
Socio Economic Objective 861205 Sheet Metal Products
HERDC Research category C1 Refereed article in a scholarly journal
HERDC collection year 2010
Copyright notice ©2010, Elsevier
Persistent URL http://hdl.handle.net/10536/DRO/DU:30033783

Document type: Journal Article
Collection: Centre for Material and Fibre Innovation
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