Springback Factor Identification Using Stress Difference Analysis
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Solution Overview
Problem
Existing methods for press forming analysis, such as CAE analysis, often fail to accurately identify the portion of a press-formed product responsible for discrepancies between predicted and actual springback amounts, leading to inefficiencies in die adjustment and springback mitigation.
Innovation Solution
A method and apparatus that analyze the stress distribution difference between a CAE analysis and an actual press-formed product, using three-dimensional shape measurement data to identify the portion causing springback discrepancies by comparing stress distributions at the forming bottom dead center and performing modified springback analyses to pinpoint the contributing factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If CAE analysis is used to predict springback amount, then springback mitigation measures can be planned before die manufacture, but the predicted springback amount may differ from actual springback amount
Solution Approach 1:
The patent changes the parameters of the CAE analysis model by incorporating actual three-dimensional shape measurement data of the press-formed product to replace or adjust the original design shape data. This parameter update allows the analysis to reflect actual forming conditions and material behavior, improving the accuracy of springback amount prediction while maintaining the time-saving benefit of pre-manufacture analysis.
Solution Approach 2:
The patent implements a feedback mechanism by using measured actual springback data from prototype or test pieces to update and refine the CAE analysis model. The measured three-dimensional shape data feeds back into the analysis system, allowing continuous improvement of prediction accuracy for subsequent die designs or adjustments.
2Productivity
If stress distribution analysis is performed using design shape data, then analysis can be completed quickly, but the stress distribution may not accurately represent actual stress state
Solution Approach 1:
The patent creates an accurate copy of the actual press-formed product by measuring its three-dimensional shape and using this measured data to construct or update the CAE analysis model. This digital copy replaces the theoretical design shape, ensuring that the stress distribution analysis reflects the actual geometry and forming conditions without requiring physical prototypes for each analysis iteration.
3Manufacturing precision
If die adjustment operations are performed to correct springback discrepancies, then form accuracy can be improved, but adjustment time and cost increase
Solution Approach 1:
The patent performs preliminary springback analysis using updated CAE models with actual shape data before final die manufacture or adjustment. By identifying potential springback issues and optimizing die design parameters in advance through accurate simulation, the need for extensive post-manufacture adjustment operations is reduced, saving time and resources.
Data Source
AI summary
A method and apparatus for identifying a portion that is a factor causing a discrepancy in springback amount between a press-formed product and a CAE analysis. The method includes a formed product driving stress distribution acquisition step of acquiring a driving stress distribution of a press-formed product, an analysis driving stress distribution acquisition step of acquiring a driving stress distribution of a springback analysis, a stress difference distribution setting step of setting a stress difference distribution, a stress difference springback amount acquisition step of acquiring a springback amount based on the stress difference distribution, a changed stress difference springback amount acquisition step of acquiring a springback amount by changing a value in a region of the stress difference distribution, and a springback amount discrepancy factor portion identification step of identifying a portion that is a factor causing a discrepancy in springback amount by comparing the acquired springback amounts.