Predicting springback in sheet metal forming: an explicit to implicit sequential solution procedure

The springback properties of sheet metals make the design of forming dies e xtremely difficult. In this work a coupled explicit to implicit finite elem ent procedure is outlined for predicting springback deformations in sheet m etal forming processes. The explicit method is initially utilized to analyz e the contact based forming operation of a production stamping process. The n, an implicit solution is performed to simulate the springback that develo ps in a blank after the forming pressure has been removed. Using this simul taneous solution technique on an actual automotive component, numerically p redicted springback deformations are found to be within 1% of production va lues. The results of the numerical investigation indicate that the coupled finite element procedure described herein can be utilized to significantly reduce the number of die prototype designs that are currently required in s heet metal stamping operations, (C) 1999 Elsevier Science B.V. All rights r eserved.