A springback energy based method of springback prediction for complex automotive parts

Springback prediction and control of complex automotive parts is a critical issue in industrial practical application. In this study, a method is proposed for characterization, prediction and control of springback based on the springback energy, which is the driving energy causing springback after stamping. A theoretical model was established and experimentally verified. A case study was conducted on the basis of an automotive part formed using aluminium alloy AA6016 sheet, and finite element method was used to obtain the necessary variables of the theoretical model. Springback energy was calculated using the theoretical model and visualized using Matlab. Results show that the magnitude of springback distortion increases with the release of springback energy. It further indicates that in addition to the average level, the distribution of springback energy has an obvious effect on the form and amount of springback. Both the reduction and homogenization of springback energy can effectively reduce springback of the part. This study facilitates the understanding, prediction, and control of springback using a new approach with springback energy that is especially applicable to complex automotive parts.