A Springback Compensation Method for Complex-Shaped Flange Components in Fluid-Cell Forming Process

The fluid-cell forming process (FFP), one of the main forming technologies in aeronautical manufactories, suffers seriously from the product quality problem due to springback. A springback compensation method is proposed particularly for complex-shaped flange parts. This method is derived from the classic Displacement Adjustment method, but differs in the way to predict the springback amount and calculate the adjusting vectors. Based on discussion on the relationship between the springback angles and the geometrical parameters of flange parts, a springback distribution function is proposed to predict springback angles of curved flanges. The springback angles are mapped to nodal adjusting vectors of the die mesh and then the optimized die is obtained. The above procedures are applied to a fuselage flange part and the result shows that this method is valid.