A Shape Error Metric for Sheet Metal Forming and Its Application to Springback

[+] Author and Article Information
B. F. Rolfe

School of Computing and Mathematics, Deakin University, Geelong, Vic 3217, Australia

M. J. Cardew-Hall

Department of Engineering, Australian National University, Canberra, ACT 0200, Australia

S. M. Abdallah

Faculty of Engineering and Architecture, American University of Beirut, Beirut, Lebanon

G. A. W. West

School of Computing, Curtin University of Technology, Perth, WA 6102, Australia

J. Manuf. Sci. Eng 125(3), 468-475 (Jul 23, 2003) (8 pages) doi:10.1115/1.1580529 History: Received April 01, 2002; Revised December 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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Diagram showing the differing effects of angle springback and side wall curl
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The variables used to measure springback of a channel: θ is the lower corner springback angle; ρ is the side wall curl radius of curvature; and β is the upper or flange corner springback angle.
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The “U” channel forming test set-up and the five controllable set-up parameters: punch travel, punch radii, tool gap, die radii and blank holder force.
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Diagram showing the distribution of the boundary points on the average channel and the determination of the mid-point of the channel. Note, that the dimensions on (a) are 150 pixels per inch, or the metric equivalent of 150 pixels per 25.4 mm. This spacing is used whenever a scanned channel is shown.
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Diagram showing how the measurements were taken for each channel with respect to a “perfect” channel. The measurements of springback are calculated by subtracting the perfect measurement from the springback affected channel. The flange length is measured from the tip of the flange to the point where the flange become the radius of the corner, whereas the extended flange length measures from the tip of the flange to the intersection of the wall and the flange line.
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The grossly emphasized PDM variational modes of the data set. Note that the positive perturbation is the dotted line and the negative perturbation is the dashed line and the significance of each mode is reflected in the weighting factor below each graph.
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Shape error surfaces where the shape error is plotted against varying tool gap and die radii while the blank holder force is held at a particular level.
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Comparing the high blank holder force average channels sets (B3D3T2 and B3D2T2) and their associated absolute b vector errors with respect to the desired shape.
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Springback error surfaces where the springback error is plotted against varying tool gap and die radii while the blank holder force is held at a particular level.




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