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Project
Springback in Stamped Aluminum Alloy Sheets for Auto-Body Panels



Description:

Sheet metal forming processes require a detailed prediction of springback to avoid assembly problems. Springback is reported in the literature to be influenced by processing parameters and material microstructure. However, understanding the rate controlling parameter for a specific application is not well understood.

Springback
Springback/Elastic recovery relates to the change in shape between the fully loaded and unloaded configurations the material encounters during a stamping operation.


Scientific Merit
• Computational sheet metal forming and stamping.
• Contribution of various material and process parameters on the formability of light-weight auto-body materials.

V-Bend Fixture Installed on Model 5800 Instron machine


Material Characterization


Taguchi Method
• ANOVA (Analysis of Variance)
Find relative contribution of each control factor to the overall measured response.
• Signal to Noise ANOVA. Find the effect of noise due to repetition of runs.


Springback Simulation Results


Status
• Bend Radius is the major contributor to springback in V- bending 6022-T4 AA.
• Microstructure, Texture and Shelf Life have very less effect on springback.
• The other factors studied have negligible effect when compared to bend radius.
• Experimental results compare well with the simulated predictions for the effect of bend radius on springback.
• The use of ANSYS implicit for solving sheet metal forming processes is limited
• The microstructure of the material used in this study was engineered for sheet metal forming process.

Future Work
• To study the effect of texture and grain size on springback by using robust sheet metal forming codes.
• What critical degree of texture in sheet metal that would require anisotropy?
• Validation of plastic anisotropy and damage of model each scale considering history of material.
• Develop exp. characterization capability at meso- and micro-scale to understand evolution of phenomena.
• Stress state, damage, microstructure-inclusion state, strain state after stamping.
• Understanding of physical phenomena.