Springback Analysis via Stress Decomposition
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Solution Overview
Problem
Current methods for analyzing springback in press-formed products are inadequate, making it difficult to accurately determine the cause of springback during the design stage, leading to increased time and costs in determining a suitable forming process.
Innovation Solution
A method involving numerical simulation that decomposes stress data into in-plane stress and bending moment components, allowing for the calculation and analysis of springback configurations, and the use of a coefficient to evaluate the influence of stress on deformation in specific areas, enabling more accurate identification of springback causes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If high-strength steel plates are used to provide thin and lightweight products, then weight reduction is achieved, but deformation resistance increases leading to greater springback
Solution Approach 1:
The patent segments the stress analysis by dividing the formed product into multiple areas and decomposing stress into in-plane stress components and bending moment components. This allows separate evaluation of different stress contributions to springback in different regions, enabling targeted analysis without requiring physical testing of the entire product.
Solution Approach 2:
The patent creates a virtual copy of the formed product through numerical simulation (finite element method) to analyze springback causes. By simulating the forming process and stress distribution in a virtual model, the invention eliminates the need for repeated physical testing with actual steel plates and dies, reducing development time while maintaining analysis accuracy.
2Loss of time
If numerical analysis is performed to estimate springback and correct die configuration, then die design time is reduced, but complete analysis of springback causes remains difficult due to nonlinear problem complexity
Solution Approach 1:
The patent divides the formed product into multiple areas and separately analyzes in-plane stress components and bending moment components. This segmentation allows the complex nonlinear springback problem to be broken down into manageable parts, improving analysis precision while maintaining computational efficiency for timely die design.
Solution Approach 2:
The patent changes the analysis parameters by decomposing stress into different components (in-plane stress and bending moment) and evaluating them separately in different areas. This parameter transformation enables more precise identification of springback causes compared to conventional holistic numerical analysis, while still completing the analysis within acceptable timeframes for die design.
3Stress or pressure
If openings or slits are provided in the formed product to remove residual stress, then springback is reduced, but product rigidity decreases leading to greater springback from slight residual stress
Solution Approach 1:
The patent replaces physical modification methods (cutting or punching openings) with a numerical simulation approach. By using finite element analysis to evaluate stress components and their contribution to springback, the invention identifies the root causes without physically altering the product, thereby maintaining product rigidity while achieving springback reduction through die configuration correction.
4Measurement precision
If actual testing with test dies and steel plates is conducted to determine countermeasures, then accurate springback analysis is achieved, but development man-hours and costs increase
Solution Approach 1:
The patent creates virtual copies of the forming process and product through numerical simulation. By analyzing stress components and springback causes in a virtual model, the invention achieves accurate analysis results without requiring repeated physical testing, significantly reducing development man-hours and costs while maintaining measurement precision.
Data Source
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AI summary
A method of analyzing a cause of springback of the invention includes: performing a forming analysis to calculate forming data of a formed product; decomposing a component into an in-plane stress component and a bending moment component; generating a before-calculation individual decomposition forming data; performing a calculation to generate an after-calculation individual decomposition forming data; analyzing a first springback configuration and a second springback configuration; obtaining a degree of influence of a stress in each of the areas with respect to springback deformation; and displaying the degree of influence with respect to the springback deformation.