Springback Analysis and Control in Forming Two-Step Rail-Shaped Sheet Metal Parts

A methodology is presented for springback analysis and control in forming two-step rail-shaped sheet metal parts. A computer system for bending and springback analysis of two-step rails is developed and described. Effects of tool corner radii, material properties and process variables on the springback behavior of two-step rails is investigated using the analysis system, and conclusions are drawn based on the sensitivity analysis result. An example of springback control is provided in obtaining an accurate shape of a given part in the design stage by changing some of the variables.