Springback Control in Complex Sheet-Metal Forming Based on Advanced High-Strength Steel

Abstract

Sheet-metal forming is one of the most important manufacturing processes in the automotive industry. This study proposes a multiobjective optimisation scheme that controls both sheet-metal formability and springback. First, the mechanical properties of DP590 steel were characterised to obtain the mechanical parameters and forming limit diagram (FLD) of DP590. Then, the FLD, thinning rate, and average springback were selected as forming quality evaluation indices. Response surface tests were then conducted for different process parameters for the A-pillar side-stiffener drawing process to analyse the DP590 steel’s formability and springback. The optimal process parameters for the drawing process were obtained using a multiobjective optimisation algorithm based on an improved particle swarm method. Finally, a springback compensation scheme was proposed based on the results of the multiprocess simulation. The scheme was applied experimentally to the A-pillar side-stiffener drawing process, and the formability and springback compensation performances verified that the scheme successfully and efficiently eliminated springback and rupture in formed DP590 steel.