An Iterative Compensation Algorithm for Springback Control in Plane Deformation and Its Application

Abstract In order to solve the springback problem in sheet metal forming, the trial and error method is a widely used method in the factory, which is time-consuming and costly for its non-direction and non-quantitative. Finite element simulation is an effective method to predict the springback of complex shape parts, but its precision is sensitive to the simulation model, particularly material model and boundary conditions. In this paper, the simple iterative method is introduced to establish the iterative compensation algorithm, and the convergence criterion of iterative parameters is put forward. In addition, the new algorithm is applied to the V-free bending and stretch-bending processes, and the convergence of curvature and bending angle is proved theoretically and verified experimentally. At the same time, the iterative compensation experiments for plane bending show that, the new method can predict the next compensation value based on the springback of each test, so that the target bending angle with the error of less than ± 0.1% and the target curvature with the error of less than 0.5% are obtained after 2‒3 iterations. This research proposes a new iterative compensation algorithm to predict springback in sheet metal forming process, where each compensation value depends only on the iteration parameter difference before and after springback for the same forming process of same material.