Prediction on Springback and Static Loading Performance of Progressive Formed Auto Stamping

Progressive stamping is an important manufacturing process in making automotive parts. Springback and static loading performance are two critical concerns in the part development. An accurate FE-based prediction on springback and static loading performance could foresee and avoid costly pitfalls in future part development. A bracket, which has tight tolerance and loading performance requirement, is chosen for this study. Implicit and explicit solutions, two major algorithms for solving the FEM motion equations, are used to simulate progressive forming process, which is composed of rib embossing and multiple bending. The springback effect is predicted on the ‘part’ formed by both implicit and explicit solutions. Measurement on the physical part shows the implicit solution can provides a more accurate prediction on both the thickness and springback. The implicit solution also consumes shorter computation time in the bending simulation while the explicit solution can finish quicker in the embossing simulation with reasonable accuracy. The part performances under static loading conditions are analyzed by the nonlinear implicit solution. The loading test on the physical part shows the prediction matches well in most cases.