Research On Springback Compensation Of Complex Shape Metal Forming Based On Corresponding Points Offset And Simulation Deviation

It is an unpreventable phenomenon as well as one of the hardest controlled defects in metal forming process that springback issue affect component quality and precision. This issue stands out in recent years with the application of high strength steel and aluminum alloy, needed to be solve urgently. With the continuous development of finite element technique in the field of metal forming, one of the effective ways in resolving the springback issue would be using numerical simulation technology. In this thesis, springback compensation of complex shape metal forming based on corresponding points offset and simulation deviation was researched, and an approach to springback effective compensate control on complex shape metal forming was put forward based on theory analysis, finite element numerical simulation, reverse engineering and experiments on the spiral blade of concrete mixer, which is significant to the quality and efficiency improvement of stamping.Firstly there was an overview on the springback compensation and control research background and significance of metal forming. And then a discussion referring to Chinese and foreign literatures was set forth to categorize current research factions and each achievements respectively.Followed by which was provided the select principles of simulation parameters used to improve the accuracy of springback simulation, based on the key technical research on numerical simulation of stamping springback. Introduced the simulation process of metal forming and springback used finite element analysis software ABAQUS, build the complex shape metal forming simulation model for the spiral blade and analyze. Then through the historical energy curve of forming and experiment data to verify the correctness of simulation model and to ensure the accuracy of the simulation results, we made the first step on this springback compensation research.Next step was focusing on the issue that die modification is on the basis of springback evaluation, and the springback evaluation of complex shape metal forming influences by different placement of the metal forming, we raised a method to select appropriate springback evaluation reference points——face-to-face method. Adopt data acquisition and data processing in reverse engineering, compared the springback evaluation result by use evaluation reference points selecting method and software's method, took actual experiments on the spiral blade to prove validity of the proposed method. Hereby we've set the foundation of coming step for springback compensation and die modification.Lastly, according to the springback problem of complex shape metal forming, and analyse the major existing springback compensation methods which is using finite element numerical simulation, then we put forth a springback compensation method for complex shape metal forming based on corresponding points offset and simulation deviation. First is to use corresponding points'vectors to achieve reverse compensating under numerical simulation iteration. Then is to make the simulating deviation compensation according to surface characteristic curves, and finally to reconstruct the surface and generate the fitting mould. By applying the method onto spiral blade experiment, it showed practical guidance on springback control and die modification for such kind of complex shape metal forming.