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Abstract
ABSTRACT
Abstract
Springback is considered as one of the main drawbacks in sheet
metal forming processes in general and especially for Aluminum
Alloys. Presently, finite element (FE) analysis is used to enhance the
understanding of sheet metal forming processes. In this study, a FE
model was built using the commercial finite element package ”Pam-
Stamp’P?”, to investigate and compensate the springback process of
an industrial part made of the Al-alloy (AA5754). Advanced material
hardening models (namely: Isotropic model, Chaboche model and
, Yoshida - Uemori model) were used and compared to accurately
predict the springback action of the proposed part. After validating
the FE model with experimental trials, the optimum process
parameters that provide parts with minimum deviation from part
design were obtained using Taguchi approach. The effects of forming
pressure, cushion pressure and holding time were also investigated.
It was found that increasing the forming pressure and/or the holding
time decreases the total springback of the part. On the other hand,
decreasing the cushion pressure decreases the total springback of the
part.
Keywords: Springback, Springback compensation, Aluminium
alloys, AA5754, Taguchi’s technique, FE Model, Chaboche
model, Yoshida-Uemori model, Cold forming parameters.