EngOpt 2008 - International Conference on Engineering Optimization

Rio de Janeiro, Brazil, 01 - 05 June 2008.

Inverse Analysis of Springback in Sheet Metal Forming by Finite Element Method

A. Behrouzi1, M. Shakeri2, B. Mollaei Dariani3
1 2

- PhD Student, Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran - Professor, Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran 3 - Associate Professor, Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran Abstract Elastic recovery of formed part in unloading known as springback causes shape error in final product of sheet metal forming processes. Several approaches have been proposed for analysis of springback and compensating its error. The springback occurs at the last step of process and the final geometry of work piece can be obtained at the end of direct process modeling. In this paper, an algorithm for inverse springback modelling using bending theory and FE modelling is presented at first. In presented approach, required conditions for inverse movement of final product toward the end of loading state are prepared. Having the product geometry at the end of loading, geometry of die parts can be designed for production of target shape. For this inverse movement in FE modelling, the optimum constrained node and balanced contact forces are proposed in this algorithm. The presented approach is verified for symmetric and asymmetric bending processes. The results have shown that this approach can model both symmetric and asymmetric processes inversely with tight tolerances. For defining the required conditions for inverse process modelling, an optimization trend is needed. An optimization algorithm for compensating springback error and iterative tool design is presented based on inverse modelling. This algorithm is verified on symmetric V-bending process and its convergence rate is compared to direct trial trend. The inverse approach shows more convergence rate in this comparison. Performing experimental test on V-bending process, the accuracy of presented algorithms is investigated. The results show that presented algorithms are efficient and accurate. Keywords: Inverse modelling, Springback, Sheet metal forming, Optimization, Tool design 1. Introduction Sheet metal forming is one of the most common manufacturing processes for used parts in various industries like inner and outer panels and stiffeners in automotive and aeronautic industries, food cans and civil engineering applications. Wide range of these products should satisfy tight tolerances compared to desired geometry. Considering high cost of tools and product in sheet forming processes, detection and controlling disturbing factors for producing precise product is so important. In most processes, geometry and configuration of die components could be obtained from the geometry of product at the end of loading. Therefore elastic recovery of formed part in unloading, known as springback is the most important factor in deviation of final product from desired geometry. Springback is influenced by a combination of various process parameters such as tool shape and dimension, contact friction condition, material properties, thickness, etc. [1]. In recent years, Finite Element Analysis (FEA) has been considered to be an effective tool for simulating the sheet metal forming processes and predicting the springback [2]. The most applied method in sheet forming analysis is incremental finite element method. By considering appropriate elastic-plastic model of material behavior, contact condition of die and work piece, numerical solution method and modeling assumptions, accurate analysis of process become possible [3]. In spite of the accuracy of incremental finite element method in analysis of sheet metal forming processes, enormous time and cost is needed for process design by this method. It is required to perform an iterative analysis to satisfy each design criteria for process design. For saving time and money, several approaches for one-step analysis of sheet forming processes is presented [4,5]. Such approaches are not as accurate as finite element method but are fast and suitable for preliminary process design. The greatest group of one-step analysis is inverse approach. In the inverse approach the final product corresponding to the desired part is assumed at the first step of analysis and by a one-step calculation, the initial process setting will be obtained. Batoz et al. [6,7] have represented an inverse approach for finding optimum blank shape to obtain the desired characteristics of product such as uniform flange width and thickness change. Unlike the finite element method that iterates for finding a blank shape to obtain the desired shape, their approach represents the blank shape in a one inverse step. Springback effect is not considered in their approach. Two groups of researches have been performed for controlling the springback deviations. The first group has focused on mechanical methods for reduction of springback by increasing sheet tension during forming process [8-11]. Applying such methods cause greater plastic zone during forming and less amount of springback occurs during unloading. Although these approaches are efficient in many processes, for many forming operations, increasing tension causes tearing of work piece. In the second group, the purpose is to compensate springback error by modification of tool design, in a way that the target shape results after springback. In such methods, the amount of springback is considerable but by accurate springback analysis and applying trial-error algorithms, this error would be compensated by correction of die geometry. In industrial practice, deformations due to springback are compensated manually by doing extensive measurements on prototype parts, and altering the tool geometry by hand, which is a time consuming process. Applying FE method several approaches for compensating springback error have been presented. Gan and Wagoner [12,13] proposed a geometrical method; Displacement Adjustment method (DA) for compensating springback error by trial modification of the die surface in opposite direction of springback. They investigated efficiency of their method compared to other approaches like Force Descriptor Method (FDM). FDM method is presented by Karafillis and Boyce for inverse design of die geometry, considering springback error [14-16]. FDM method has convergence and accuracy problem in processes with asymmetric physics and large amount of springback; therefore it is only efficient for symmetric problems [12,16]. DA method has some advantageous compared to FDM [12] but could not converge to the curved features in the side wall area [17]. Similar approaches have been presented by Cheng et al. [17], Wu et al. [18], Anagnostou [19] and Lingbeek et al. [20].

Inverse analysis of springback could be applied for obtaining process geometry in a way that the final part corresponds to desired shape. In this paper, a springback analysis approach is presented based on inverse modeling of springback from target shape. The presented approach could be applied in a process design trend for producing the target shape after springback. 2. Inverse Modeling of Springback For performing inverse modeling of springback, geometry of final product should be considered as initial part geometry. Some consideration is required to obtain final loading state from final product by inverse springback analysis. For inverse simulating of springback, effective parameters on springback should be detected and applied on initial model properly. These effective parameters comprise residual stress, contact stress between die component and work piece, material behavior, constrains and so on. The way of applying these features and inverse modeling of unloading step is depend on analysis method. In this paper, by elastic-plastic theory of bending, the inverse springback analysis of free bending process is carried out at first. For development of inverse modeling of springback to analyze more complicated processes, basic concepts for adaptation of this method with finite element analysis is presented. Inverse analysis of springback by using FEM is applied for three-dimensional bending process to verify the efficiency of this approach. For verification of the presented approach, inverse modeling of unloading step of a known process is required to compare the geometry of process at end of loading step with the obtained geometry from inverse springback analysis. Analytical solution of bending process is presented in many researches [21-23]. For inverse analysis of springback in V-free bending process, state of plain strain and negligible shear deformation is assumed. By dividing the total axial strain into elastic and plastic part, it can be written as:

x = e + p =

(1 2 ) x + p E

(1)

where e, p , E and are elastic strain, plastic strain, Youngs modulus and Poissons ratio for plane stress state respectively. Required bending moment can be calculated as:

x y dA = M
A

(2)

Axial strain and axial stress can be obtained as:

x =

2t2 24 y t 2 12 M (1 2 ) y p dy + t 3 p ydy + t y Ebt 3 y

c c

(3) (4)

x =

E p 2E t 2 24Ey t 2 12My p dy + (1 2 )t 3 p ydy + bt 3 (1 2 ) 2 (1 )t y y

c c

where b and t are width and thickness of sheet respectively. Bend radius after springback can be written as:

1 12 M (1 2 ) bt 3 E 1

(5)

where and are bending radius before and after springback respectively. Knowing thickness and width of sheet and considering material behavior as below, analysis of V-bending for various bending angle and radius become possible.

x =

E x n K x

for x Y for x Y

(6)

where K, n and Y are hardening coefficient, hardening exponent and corresponding strain to elastic limit respectively. For inverse springback analysis of free bending process, initial configuration corresponding to desired and is considered. Residual stress state is distributed on initial geometry. After applying the required moment for sheet bending that is evaluated from equation (6), the inverse springback analysis would be carried out. Corresponding radius and angle of bending (, ) for resulting desired radius and angle of bending (, ), could be obtained from process configuration at the end of inverse analysis. For evaluating required bending moment and residual stress, forward analysis of bending process is required. Process setting for this step is defined in a way that desired radius and angle of bending (, ) is resulted at the end of loading step. Although the evaluated bending moment and residual stress is not exactly the same as related results of designed process by inverse analysis, the difference is not considerable. If high precision results is required for production of desired shape, in the next step, moment and residual stress should be evaluated from designed configuration by inverse analysis (, ). The inverse algorithm is shown in figure 1. For investigating convergence rate of inverse springback analysis a program has been prepared for analysis of bending process by theory of bending. By this program analysis of bending process for ambient process configuration (, ) become possible. Two algorithms are prepared for compensating springback error, the first one is based on modification of bending radius and angle in each iteration (direct method) and the second one is based on inverse springback analysis method.

Start Obtaining (, ) of punch, using Inverse Approach Target (, ) & t Comparing obtained (, ) and target (, )

Evaluating final moment using load or deformation control algorithm

Evaluating final product (, )

Convergence ? Yes No End

M
r t

M
'<

'

Residual Stress

Figure1. Algorithm of inverse springback analysis for compensating springback error in V-bending process

3. Inverse Finite Element Modeling of Springback

By adaptation of inverse springback analysis with finite element method, complicated processes and three-dimensional processes could be analyzed for compensating springback error. Presentation of an algorithm for inverse springback analysis of three-dimensional process by using FEM is the main purpose of this section. There are two major steps in a sheet metal forming process: loading step and unloading step. In most cases displacement field of sheet in loading step (Dl) could be obtained from die geometry and assigned punch displacement. The displacement field in unloading step (Dsb) is due to springback phenomena. Obtaining the desired geometry at the end of unloading step, sum of loading displacement and springback displacement should be equal to target displacement as below:

r r r D ut = D lt + D sbt

(7)

where Dut, Dlt and Dsbt are total displacement, loading displacement and springback displacement respectively at the optimum process for producing the target shape. Evaluation of Dsbt is not possible before performing or modeling the whole optimum process. Inverse modeling of springback is a movement from final equilibrium state (end of unloading step) to middle equilibrium state (end of loading step). Therefore for efficient inverse modeling of springback, required conditions for satisfying equilibrium should be considered. 3.1. Algorithm of inverse springback modeling by finite element method Two main subjects cause major problems in convergence and accuracy of inverse modeling of springback. The former is unbalanced internal and external forces and the latter is large nodal rotation in unloading step. The presented approach in this paper deals with these two subjects to become suitable for both symmetric and asymmetric processes also for processes with large amount of springback. For inverse FEM modeling of springback, following steps should be adapted: The meshed part at the end of forming process should be rebuilt. Defining the initial coordinates of nodes in flat sheet by X 0 , the coordinates of each node could be obtained as below:

r r r r X u = X 0 + D l + D sb

(8)

~ Final stress state of formed sheet (residual stress res ) should be defined as initial condition for inverse modeling of springback. Therefore the stress field at the end of loading step could be obtained as:

~ ~ ~ li = res + sbi

(9)

~ ~ where li and sbi are calculated stress field at the end of loading step and calculated stress change from inverse modeling respectively. Contact forces (Fc) between die and sheet (calculated from direct modeling) should be exerted on prepared model in an inverse loading step. Proper node should be constrained for the least rigid body rotation. Finding such node requires a search algorithm between all nodes for the least rotation from the end of loading step to the end of unloading step. This algorithm is prepared by calculating nodal rotation in unloading step and searching for the minimum value. Implicit analysis considering nonlinear geometry with fixed coordination of exerted force should be performed. According to virtual work principle, the internal work performed during inverse movement from end of process to the end of loading step should be equal to the external work performed in the same period. Wint = Wext
In which internal work, Wint and external work, W ext could be obtained as below: (10)

Wint = ( : d )dV
e =1 Ve

f
0

(11)

Wext = ( Fc du )d
e =1 e 0

uf

(12)

where N, , f , Ve, Fc, e and uf are number of elements, stress function, final strain, element volume, external force vectors, boundary and nodal displacement at the boundary respectively. In inverse model, the residual stress could be considered as initial stress field. Therefore the stress function could be represented as below:

Start

Creating inverse model and ~ applying res and Fc

~ Evaluation of sbi and D sb from inverse model

Target Shape ( D ut )

Finding suitable nodes for being constrained in inverse modeling

Comparing obtained geometry and stress field from inverse modeling by those of direct modeling

Direct modelling of process with assuming

Dl Dut

~ ~ Calculation of li , res and Fc by explained implicit modelling of unloading step

End

Xi End of loading

Fc ~ l

End of unloading

~ ~ u = res
Figure 2. Algorithm of inverse springback analysis by finite element method

~ ~ = res + ( )
Brief algorithm and schematic model of inverse springback analysis is shown in figure 2.

(13)

3.2. Calculation of contact forces As mentioned before, the most important factor that makes convergence and accuracy problems in inverse springback analysis (especially in asymmetric processes) is unbalanced contact forces between die and work sheet. Therefore the balanced contact forces have major importance in inverse springback modeling. Modeling of sheet metal forming processes is usually performed by explicit finite element method. Although explicit FEM has some advantageous in convergence and solution time compared to implicit FEM, but equilibrium in contact condition is not rigidly assigned in explicit contact modeling. Therefore the calculated contact forces from explicit formulation, does not satisfy static equilibrium of work piece. In modeling of symmetric problems usually the half of geometry is modeled, therefore in symmetric processes the unbalanced contact forces affect the reaction forces at constrained nodes on symmetry axis. By this change of reaction forces at the constrained nodes, the static equilibrium of whole model is satisfied, although the calculated contact forces are not the exact values. Therefore the inverse springback analysis with unbalanced contact forces is possible for symmetric processes but has low accuracy due to deviation of calculated contact forces from the exact values. For asymmetric problems the unbalance of contact forces produces rigid body motion and causes divergence of inverse springback analysis or great errors in inverse calculated amount of springback. According the above, applying the inverse springback analysis with unbalanced contact forces in a compensating springback error algorithm, results low convergence rate in symmetric problems and usually diverge in asymmetric problems [12]. In this paper an algorithm for balancing of contact forces is presented by complex explicit-implicit direct modeling of process. For balancing of contact forces, in direct analysis of process, below steps should be followed: Explicit modeling of process until the end of loading step should be performed. Penalty contact modeling is used in explicit modeling of loading step. Following objects from work sheet should be read from explicit modeling of loading step and be saved in a text file by a subroutine: - Stress components at the end of loading step. - Coordinates of each node at the end of loading step. - Interface nodes that are in contact with die components at the end of loading step. Implicit modeling of unloading step in two substeps should be performed. These two substeps are as below: Substep1: - An initial model corresponds to the end of loading step is created. For this purpose, coordinates of nodes are read from saved text file by a prepared subroutine. - Saved stress components in previous step are applied as initial stress state in created model. - Saved interface nodes in previous step constrained in all three directional coordinates. Performing implicit analysis in this substep represents the balanced contact forces at the end of loading step, because in implicit analysis static equilibrium is always satisfied.

Start No Convergence check comparing obtained Du with Dut Yes

The last configuration of die is appropriate for producing target shape

Target Shape ( D ut ) End Direct modeling of process with assuming Dl Dut Direct modeling applying obtained Dl from previous step

~ ~ Calculation of li , res and Fc by explained implicit modeling of unloading step

Inverse modeling considering Du=Dut following section 3.1and obtaining Dl

Figure 3. Algorithm of compensating springback error by inverse FE modeling

Substep2: - All constrained nodes in previous substep are released. - One node is fully constrained. For convenience in inverse springback analysis, the obtained node in section 4.1 is chosen. Choosing this node cause minimum rigid body rotation in unloading step therefore unloading step comprises springback deformation only. Performing implicit analysis in this substep represents the final geometry of work sheet after springback. By applying above algorithm for balancing the contact forces, the exact equilibrium of work sheet become available. Therefore the inverse springback analysis becomes applicable for both types of symmetric and asymmetric processes. Also by applying the search algorithm for minimum rotation nodes the presented inverse approach is capable of springback analysis for processes with large amount of springback. 3.3. Algorithm for Compensating Springback Error The presented algorithm can be used in an optimization algorithm to compensate springback error as follow: 1. Target shape is considered as final product and presented algorithm in section 3.1 is applied to model springback inversely. 2. Obtained geometry from previous step is used for configuration of die in next direct modeling. 3. Final product of previous step is compared to target product. If the convergence limit is not achieved, next step should be followed. 4. Step 1 is repeated by replacing parameters explained in section 3.2 (contact forces, residual stresses,) with those obtained in step3. 5. Steps 2 to 4 are repeated until convergence criterion is satisfied and final product corresponds to target geometry at desired tolerance. The inverse algorithm for compensating springback error is shown in figure 3. 4. Results For investigation of presented inverse approach, symmetric V-bending process and asymmetric bending process are verified. For Vbending process, bending theory presented in section 2 and inverse FE modeling presented in section 3 are applied. For asymmetric bending process only inverse FE modeling is applicable. 4.1. Inverse analysis of V-bending process For this process St-12 sheet with 1mm thickness is considered. In figure 4, die setting and dimensions for considered process is shown. By performing tension test on applied sheet, stress-strain curve for FE modeling and analysis by bending theory is obtained. According to obtained stress-strain curve, hardening coefficient (K) and hardening exponent (n) are calculated as 630 Mpa and 0.337 respectively. The process shown in figure 4 is analyzed by represented bending theory in section 2. Springback angle is obtained 4.1 and obtained bending radius after springback is 2.143 cm. For achieving the die setting for target bending angle of 90 and bending radius of 2.05 cm, the presented inverse algorithm shown in figure 1 is applied. The inverse approach represents final 90 bending angle and 2.05 cm bending radius in two trial steps for a definite precision. The forward procedure represents the desired results for the same precision in three trial steps. The convergence diagram of inverse and forward procedure is shown in figure 5. It can be seen the inverse approach has more convergence rate compared to forward approach. The proposed angle and radius by inverse approach in each try is shown in figure 6.

Figure 4. Bending die plan and dimensions

a) Inverse algorithm

b) Forward algorithm

Figure 5. Convergence diagram for V-bending process a) Inverse algorithm, b) Forward algorithm

Proposed Obtained

Figure 6. Proposed and obtained bending angle and radius by inverse approach Applying presented approach in section 3.1, the inverse FE modeling of above process is performed. Considering the bending angle as 90 and bending radius as 2.05 cm, springback angle is obtained 3.5. Results of forward and inverse FE modeling of this process is shown in figure 7.

93.5
(1) (1)

b) (2) a) Forward analysis (2) b) Inverse analysis

Figure 7. Deformed shape at the end of loading and unloading step: a) Forward analysis, b) Inverse analysis

Figure 8. Geometry at the end of loading step, after explicit springback and after implicit springback In figure 7-a. displacement field of 90 bending process at the end of loading and unloading step have been shown. At the end of loading step, shown in figure 7-a-1., the bending angle is set to 90. Bending angle at the end of unloading step (after springback) has been obtained 93.5 (figure 7-a-2). 4.2. Inverse analysis of asymmetric bending process According to sensitivity of inverse approach to asymmetry and large amount of springback, asymmetric bending of HSLA sheet is considered. Accuracy of presented inverse approach is verified at first. Achieving this purpose, a performed direct modeling of asymmetric process, is modeled inversely following algorithm shown in figure 2. Comparing the obtained geometry from inverse modeling by geometry of work piece ate end of loading from direct modeling, the accuracy of inverse approach is verified. After that by performing presented algorithm for compensating springback error (figure 3), tool geometry for production of desired shape is presented. In figure 8, geometry of work sheet at the end of loading step, obtained final shape from full explicit modeling and explicit loadingimplicit unloading are shown. As is shown, the implicit springback modeling represents similar results obtained from explicit springback modeling. In figure 8, obtained geometry from inverse springback analysis is compared to the geometry of work sheet at the end of loading step in direct modeling. As it can be seen two curves follow each other nearly. The product shape shown in figure 9 is assumed as target shape and performing inverse springback compensating algorithm (figure 3), die geometry is modified in each trial. Results of this algorithm for first and second trial are compared to target shape and product of direct modeling, in figure 10. As it shown the product geometry of second trail process corresponds to target geometry nearly. Proposed die geometry in each trail and in direct model is shown in figure 11. Comparing the product geometry of first and second trail, it can be concluded that in further trials the product shape error will be decreased. 4.3. Experiments Free bending process has been experimented for checking the validity of applied analysis method by comparing the analysis results with test results. For defining the material behavior of used strip in bending process, uniaxial tension test has been performed on applied sheet (St-12: thickness=1mm). Two bending test is arranged for investigating validity and accuracy of inverse springback analysis. In the first test, die dimensions and punch displacement has been defined corresponds to shown dimension in Fig. 4. Die setting and punch displacement in this case defined in a way that bending angle becomes 90 at the end of loading step similar to performed modeling. The obtained work piece from first test has been shown in figure 12-a. The obtained bending angle is 93.6. The test result corresponds to obtained value in section 4.1 from FEM analysis.

Figure 9. Comparison of inverse springback analysis and direct analysis results

Figure 10. Comparison obtained product shapes in each trial with target shape

Figure 11. Proposed die geometry by inverse algorithm in first and second trial In the second test, applying the result of inverse springback analysis, punch displacement has been set to obtain 90 bending angle, at the end of unloading step. As is shown in figure 12-b, 90 bending angle has been resulted from second bending test. According to obtained results from the performed test and analysis, it can be seen the inverse springback analysis could be applied accurately in sheet bending process design for compensating springback error. 5. Conclusion Inverse analysis of springback (starting from final shape toward end of loading step) could have several advantages. Definite final shape of work piece is the major advantage of inverse springback analysis compared to forward analysis. In the present paper a modified approach for inverse modelling of springback is presented and verified for both symmetric and asymmetric bending processes. Also the accuracy of its results is investigated for process with large amount of springback. In all cases the obtained results are accurate.

93.6

90

a) First test (93.6 bending angle)

a) Second test (90 bending angle)

Figure 12. Final products of bending tests

After verification of presented inverse approach, it is used in an optimization algorithm for modification of die geometry to compensating springback error. Former is convergence rate of algorithm, latter is the convenience of algorithm for defining tool geometry for next try. Considering sensitivity of inverse approach to unbalanced forces, If this sensitivity is not managed correctly, causes divergence or low accuracy, especially for asymmetric processes insofar as this approach become useless for asymmetric processes and processes with large amount of springback. In the presented approach, some strategies are proposed for balancing the contact forces. Also proper nodes for being constrained are proposed. Furthermore by exerting the residual stress field at the beginning of inverse analysis, static equilibrium of model and inverse analysis of stress field is become available. According to obtained results, presented algorithms have high convergence rate and the target shape with high accuracy is achieved in few trial steps. Also presented algorithm for optimization of die geometry based on FE modelling is capable of producing modified model for the next try. All FE analysis in presented approach except forward explicit modeling, are based on implicit formulation. Required time for performing implicit analysis is negligible compared to direct explicit modeling step. Therefore required total time for this approach is about the required time for direct explicit modeling of whole process. Presented algorithms for inverse FE modelling of springback and optimizing its error are three-dimensional approaches; therefore a wide range of sheet metal forming processes could be analyzed and optimized by these algorithms. Considering above advantages, applying these algorithms are helpful in tool design for sheet metal parts with high dimensional accuracy. 6. 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