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The need for car body structures of higher strength and at the same time lower weight results in serious challenges for the stamping process. Especially the use of high strength steel and aluminium sheets is causing growing problems with regard to elastic springback. To produce accurate parts the stamping dies must be adjusted more or less by the amount of the springback in the opposite direction. For this purpose well-known software solutions use the Displacement Adjustment Method or algorithms which are closely based on that method. A crucial issue of this method is that the generated die surfaces deviate from those of the target geometry with regard to surface area. A new Physical Compensation Method has been developed and validated which takes geometrical nonlinearity into account and creates compensated die geometries with equal-in-area die surfaces. In contrast to the standard mathematical/geometrical approach, the adjusted geometry is generated by a physical approach, which makes use of the virtual part stiffness. Hereby the target geometry is being deformed mechanically in a virtual process based on the springback simulation results by applying virtual forces in an additional elastic simulation. By doing so better part dimensions can be obtained in less tool optimization loops.

New method for springback compensation for the stamping of sheet metal components