Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming

Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the anti-collision beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending process is established, indicating that local wrinkles and cross-section distortion are prone to occur in the transitional region between the straight and bending zones. Additionally, an iterative compensation method is implemented to ensure that the post-springback dimensions of the beam closely match the designated design specifications. Finally, after the trial production of the beam, the springback value has been measured and found to be in line with the simulation prediction, thereby confirming the accuracy of both the material's properties and the forecasting model. The developed model has adjusted the die design to match the intended objective shape of the beam and successfully fulfilled the dimensional error tolerance requirement of 2mm, while also achieving cost reduction and a shortened design cycle.