Springback Reduction in Stamping of Front Side Member with a Response Surface Method

Springback is a common phenomenon in sheet metal forming since the elastic recovery of the internal stresses is induced after removal of the tooling. The numerical analysis of springback is a complicated time-consuming job and its result is greatly effected by a type of the yield function, finite elements used and the constraint condition for eliminating a rigid body motion. In this paper, optimization of the draw-bead force is carried out utilizing the response surface method in order to reduce springback and improve shape accuracy of a deep drawn product. In the optimization process, the tendency of springback is evaluated qualitatively without springback simulation usually done with the implicit solving scheme. Instead of springback simulation, the amount of stress deviation along the thickness direction in the deep drawn product is used as an indicator of springback. The stamping process is analyzed for a front side member formed with advanced high strength steel (AHSS) sheets such as DP60. The analysis procedure fully covers the binder-wrap, stamping, trimming and springback processes with the commercial elasto-plastic finite element code LS-DYNA 3D. The effect of the restraining force of draw-beads is confirmed with the decreased stress deviation. The analysis result shown in the final springback simulation demonstrates that the present analysis provides a guideline for controlling the evolution of springback based on the finite element simulation of complicated auto-body members