Die Face Engineering based Springback Compensation

Strategy and Implementation

Arthur Tang, Wing Lee, Jeanne He, Jinbo Xu, Kesu Liu and Chin Chun Chen
Engineering Technology Associates, Inc.
Troy, Michigan
U.S.A

Abstract. Springback or shape change has been one of the major challenges in sheet metal fabrication, particularly with increase
application of high strength steel (HSS) and aluminum alloys in automotive stamping. Springback, an elastic material recovery
after the unloading of stamping tools, causes variations and inconsistencies of final part dimensions. Minor or mild springback
usually can be corrected in the re-strike process. Excessive springback must be corrected so the part will be produced within the
given design tolerance and dimension. The commonly used Spring Forward approaches and shape compensations such as overcrown and over-bending are proven effective to alleviate excessive springback. To enhance these approaches, a new strategy of
Die Face Engineering (DFE) based processing is proposed to quickly and easily to achieve the maximum allowable
compensation using the under cut (or die lock) as the primary [Link] implementation of the die face compensation through
iterative FEA calculation, automatic surface mapping, projection and manual morphing are crucial to meet production
environment requirements in terms of generating NC quality CAD surfaces of the compensated or morphed die face. In this
paper, the strategy of the die face compensation with the consideration of the under cut criteria is presented. The implementation
of various processes to enable user to perform the die face compensation task in a production environment is also discussed.
Finally, two examples are shown to demonstrate the implementation of the proposed springback compensation scheme based on
the combined CAE/CAD methodology.

analysis by different numerical techniques [5-11].

However, the approach yields limited success due to the
lack of development in both numerical techniques and
experimental understanding. To further understand
prediction of springback using FEM simulation, many
research groups such as Liu et. al. [12-14], Onipede et. al.
[15], Zhu and Maker [16-17] have carried out more
investigations on FEA of springback analysis.

INTRODUCTION
In recent years, the advances in automotive manufacturing
have resulted in increasingly application of lighter gauge
high strength steel (HSS) and aluminum alloy sheets in
automotive stampings, as opposed to the conventional mild
steel grades. The application of such advanced materials
has posed challenging issues during sheet metal fabrication.
One of the greatest challenges is springback. Springback or
shape change is an elastic material recovery after the
unloading of stamping tools and removal of stamped parts
from stamping tools. It causes distortions and dimensional
inconsistencies of stamped part.

Springback causes undesirable final part quality and creates

difficulties in downstream assembly processes. In addition,
it slows down new product launches, increases changeover
time and the associated cost. In stamping production, minor
or mild springback is usually corrected with the re-strike
processes. As for excessive springback, correction must be
made so the stamped part will be produced within the given
design tolerance and dimension. The commonly used
Spring Forward/Backward and shape compensations such
as over/under-crown and over/under-bending have been
proven effective to alleviate excessive springback.

For over two decades, numerous researchers have studied

springback phenomena. For examples, Ayres [1], Davies
[2], Hayashi [3], and Shi [4] conducted experiments to
study springback behavior. The popularity of FEM
simulation of the sheet metal stamping process since 1990s
has encouraged many researchers to attempt springback

In this paper, the strategy of the die face compensation with

the consideration of the under cut criteria is presented.

CP778 Volume A, Numisheet 2005, edited by L. M. Smith, F. Pourboghrat, J.-W. Yoon, and T. B. Stoughton
2005 American Institute of Physics 0-7354-0265-5/05/$22.50

314

Additionally, the implementation of various processes to

enable user to perform the die face compensation task in a
production environment are discussed. These processes
include automatic surface mapping, projection and manual
morphing. The die face compensation of U-Channel and
Rail are illustrated to demonstrate the implementation of
the proposed springback compensation scheme based on
the combined CAE/CAD methodology.

functions available in the software. The DFE contains both

semi- and fully-automated features such as element fillet,
reverse trimming, outer smooth, binder generator,
addendum generator, morphing, tipping, surface mapping,
draw bar, sausage and so on. Some of these features related
to the topic are briefly discussed in the following section.

Morphing
Line, surface and mesh morphing are all offered in the DFE
module for stamping engineers to easily manipulate Punch
Opening Plus (POP) lines, reverse trimming functions,
addendum and binder surface design.

DIE FACE ENGINEERING

The eta/DYNAFORM stamping simulation software is
packaged with both the explicit and implicit finite element
analysis (FEA) solvers LS-DYNA [21,22] which produce
springback results of a particular deformed blank on a die
face. The Die Face Engineering (DFE) is a toolbox
provided in eta/DYNAFORM for incremental stamping
FEA users to design and engineer the draw die, including
binder and addendum from the part geometry. The DFE
module was developed to enable the users to quickly derive
a suite of binder and addendum surfaces as a baseline
tooling design for further formability feasibility study. As a
result, it reduces iteration time for tooling design and
development cycles. At the end, the module helps to reduce
the associated cost.

Tipping
The tipping function places the part into die position from
the design position. In DFE, tipping process can be carried
out manually and/or automatically. After tipping process,
the undercut can be identified by plotting the tipping
contour. In addition, the draw depth is estimated, per the
reference of the Point of the First contact.
Surface Mapping
This function enable user to map the original CAD Die
Surfaces to the morphed mesh and/or springback
compensated mesh. As shown in Figure 1, the Surface
Mapping function in DFE provides three types of
projection methods. The Adaptive Normal, Mesh Normal
and Surface Normal enable surface projection along the
adaptive normal orientation, mesh normal and surface
normal, respectively.

The architecture of DFE in eta/DYNAFORM Version 5.2

[23] provides one-code, one-environment pre-processor for
stamping simulation. It allows the user to easily design and
re-engineer the die tooling using the numerous automated

FIGURE 1. An illustration of Surface Mapping dialog in eta/DYNAFORM DFE module.

315

The User Graphic Interface (GUI) of DFE based

springback compensation is shown in Figure 2. The GUI
enables implementation of die face compensation using the
springback results from original tooling. It consists of four
major areas: (a) Select Nodes (b) Undercut Option, (c)
Compensation Scaling Factor and (d) Tool Mapping.

DIE FACE ENGINEERING BASED

STRATEGY TO COMPENSATE
SPRINGBACK
The Springback FEA results, include the forces, stress,
strain, displacement and displacement vector are the criteria
for determining the amount of springback compensation
needed on the die surface using a method generally
referenced as Spring Forward [18-20]. To enhance the
approach, a new strategy of Die Face Engineering (DFE)
based springback compensation methodology is proposed
to quickly and easily to achieve the maximum allowable
compensation using the under cut (or die lock) as the
primary criteria. Furthermore, the strategy mainly focuses
on FEM mesh.

The Select Nodes function allows selection of local or

global zones in the sprung parts for springback
compensation calculation. The Undercut Option enables
automatically backdraft detection and avoidance. An
example of implementation of Undercut Option in
springback compensation is illustrated in Figure 3. As
shown in Figure 3a, the undercut (boxed regions) takes
place without implementation of Undercut Option during
springback compensation process. On the other hand, the
undercut is check and avoided during the springback
compensation process if the Undercut Option is turned on.

FIGURE 2. The springback compensation GUI packaged in DFE.

316

Part after
compensation

Part after
forming

(a)

(b)

FIGURE
3. An
example
ofofspringback
Without
Undercut
Option
(b) Undercut
With Undercut
FIGURE
3. An
example
springback compensation
compensation (a)(a)Without
Undercut
Option
(b) With
Option. Option.
compensated
tool tool
meshmesh
is then
conduct
further further
compensated
is used
then toused
to conduct
formability
and and
springback
analysis.
If the compensated
formability
springback
analysis.
If the compensated
tool
mesh
produces
springback
that isthat
within
design
tool
mesh
produces
springback
is the
within
the design
tolerance, the original CAD surfaces will be mapped onto
tolerance, the original CAD surfaces will be mapped onto
the compensated tool mesh using Surface Mapping
the compensated
meshOtherwise,
using the
Surface
function
provided in DFEtool
module.
die faceMapping
function provided
module.
Otherwise,
the die face
compensation
process in
is DFE
repeated
following
by another
compensation
processanalysis.
is repeated following by another
formability
and springback

Compensation
ScalingFactor
Factor isis the
the controlling
controlling
The The
Compensation
Scaling
variables that determine the amount of springback
variables that determine the amount of springback
compensation in X, Y, Z or ALL directions during the
compensation
X, Y, Z orprocess.
ALL The
directions
during
the
springbackincompensation
controlling
variables
springback
The controlling
variables
includecompensation
displacement,process.
displacement
vector, stress
and
include
displacement,
displacement
stress the
and
strain.
Depending on
the direction vector,
of springback,
[Link]
Depending Scaling
on the Factor
direction
of defined
springback,
the
can be
as either
positive or negative
Compensation
Scaling values.
Factor can be defined as either
positive or negative values.

formability and springback analysis.

Through the iterative FEA simulations and die face
compensation
processes,
one FEA
can obtain
a die faceand
that die face
Through the
iterative
simulations
generates
quality stamped
part. one
Finally,
compensation
processes,
can automatic
obtain asurface
die face that
mapping, projection and manual morphing are carried out
generates quality stamped part. Finally, automatic surface
simultaneously to generate the NC quality CAD surfaces of
mapping,
projection and manual morphing are carried out
the compensated or morphed die face. The flow chart of
simultaneously
to generate
the NC
quality
CAD surfaces
of
DFE
based springback
compensation
process
is shown
in
the compensated
or morphed die face. The flow chart of
Figure
4.

Upon the completion of springback compensation, the

mesh will beofprojected

onto the
compensated part
Upon tooling
the completion
springback
compensation,
the
mesh using the Tool Mapping function. After the tool mesh
toolingis mapped
mesh will
be
projected
onto
the
compensated
part
onto the compensated part mesh, the Tool Repair
mesh function
using thecanTool
Mapping
[Link]
the tool mesh
be utilized
to manually
semi-automatically
is mapped
compensated
part mesh,tool
the mesh.
Tool Repair
repair onto
or the
smooth
the compensated
The
function can be utilized to manually or semi-automatically
repair or smooth the compensated tool mesh. The

DFE based springback compensation process is shown in

Figure 4.

317

CAD Data

Pass
Springback
Not Pass
Define Undercut Envelop

Compensate Part Mesh

Map Compensated Mesh to Die Face

Smooth Die Face & Binder Surface

eta/DYNAFORM Quick Setup

Not Pass

Re-Analysis
Formability+Springback
Pass
Mapping Die Surfaces

Tool Making
FIGURE 4. A flow chart showing Die Face Engineering based springback compensation strategy.

318

symmetry, only half blank geometry is modeled. The blank

material is HSLA250. A 25kN binder force is applied.

IMPLEMENTATION OF DIE FACE

ENGINEERING BASED SPRINGBACK
IMPLEMENTATION OF DIE FACE
COMPENSATION

symmetry, only half blank geometry is modeled. The blank

As indicated
in Figure
5, thebinder
formed
strip
sprung backward
material
is HSLA250.
A 25kN
force
is applied.

ENGINEERING BASED SPRINGBACK

by approximately 9* after springback analysis. The DFE

COMPENSATION
Two
benchmark examples are conducted to demonstrate
the implementation of DFE based springback compensation
strategy.
The results
of these
benchmarks
are briefly
Two benchmark
examples
are conducted
to demonstrate
discussed.
the implementation of DFE based springback compensation

springback
compensation
are backward
carried out to
Asbased
indicated
in Figure
5, the formedprocesses
strip stsprung
the springback.
After the analysis.
1 compensation,
byalleviate
approximately
9o after springback
The DFE it is
discovered
thatcompensation
the large compensation
based
springback
processes arescaling
carried factor
out to has
resultedthe
in spring
forward
of the formed
strip. The itvalue
alleviate
springback.
After
1st compensation,
is of
discovered
that the
large compensation
factor
compensation
scaling
factor is thenscaling
reduced
in has
the 2nd
resulted
in springand
forward
of the formed
strip. The reduced
value of with
compensation
the springback
is gradually
compensation
scaling
factor
is then
the original
2nd
the dimension
of the
sprung
stripreduced
close toin the
compensation
and
the
springback
is
gradually
reduced
with
formed strip.
the dimension of the sprung strip close to the original
formed strip.

strategy. The results of these benchmarks are briefly

discussed.
Simple
U-Channel
A simple UChannel forming simulation is set up using
Simple U-ChannelQuick Setup module. The blank
eta/DYNAFORM
A simpleis U1.0
-Channel
simulation
usingto
geometry
mm xforming
30.0 mm
x 175.0is set
[Link]
eta/DYNAFORM Quick Setup module. The blank
geometry is 1.0 mm x 30.0 mm x 175.0 mm. Due to
nd

(2

Die Face
Compensation)

Part after Springback

nd
(2 Compensation)

Part after Springback

st
(1 Compensation)

R5mm

Die Face
(Original)
Part after Forming
(Original)

Part after Springback

(Original)
70mm

R5mm
130mm
FIGURE 5. Implementation of DFE based springback compensation on simple U-Channel.

Section A-A

Springback
(Original)

Forming
(Original)

Forming
(Compensation)
Springback
(Compensation)

A
FIGURE 6. Implementation of DFE based springback compensation on Structural Rail.

319

Automotive Structural Rail

The forming simulation and springback analysis are
conducted for structural rail using DP600. After the
springback analysis, severe springback is found on one end
of the formed structural rail (shown in Figure 6). Therefore,
the DFE based springback compensation is carried out to
further demonstrate its capabilities to reduce springback
severity. The springback analysis reveals the reduction of
springback at section A-A after one iteration of springback
compensation is performed.

CONCLUSION

3.

Hayashi, Y. and Takagi M. Analysis of Sidewall Curl

in Draw Bending of High Strength Steel Sheet, J. of
the Iron and Steel Institute of Japan, Vol. 68. No. 9,
pp. 110-117 (1982)

4.

Shi, M. Effects of Design and Stamping Process

Variables on Sidewall Curl, Proc. Of IBEC 95, pp.
71-78 (1995)

5.

6.

Kutt, L., Nardiello, J., Ogilvie, P., Pifko, A and

Papazian, J. Non-Linear Finite Element Analysis of
Springback, Commun. Numer. Meth. Engng., 15, pp.
33-42 (1999)

9.

Makinouchi, A., Nakamachi, E., Onate, E. and

Wagoner, R. H., Numerical Simulation of 3-D Sheet
Metal Forming Processes, Proc. 2nd International
Conference, NUMISHEET 93, Isehara, Japan (1993)

12. Yao, H., Liu, S.-D., Du, C., Hu, Y. Techniques to

Improve Springback Prediction Accuracy Using
Dynamic Explicit FEA Codes SAE Technical Paper
No. 2002-01-0159 (2002)
13. Liu, S.-D. et. Al. A Study on the Effects of
Simulation Parameters on Springback Prediction
SAE Technical Paper No. 2000-01-1109, pp. 135-142
(2000)

Ayres, R. A. SHAPENET: A Process to Reduce

Sidewall Curl Springback in High Strength Steel
Rails, J. of Applied Metalworking, Vol. 3, pp. 127134 (1984)
Davies, R., Sidewall Curl in High Strength Steels, J.
of Applied Metalworking, Vol. 3, pp. 120-126 (1984)

8.

11. Pourboghrat, F., and Chu, E. Springback in Plane

Strain Stretch Draw Sheet Forming, Int. J. Mech.
Sci., Vol. 36, No. 3, pp. 327-341 (1995)

REFERENCE

2.

Karafillis, A. P. and Boyce, M. C. Tooling Design in

Sheet Metal Forming Using Springback Calculations,
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10. Narasimhan, N. and Lovell, M. Predicting

Springback in Sheet Metal Forming: An Explicit to
Implicit Sequential Solution Procedure, Numerical
Methods for Design and Analysis, Vol. 33, pp. 29-42
(1999)

The springback or shape change has been the greatest

changes in the stamping industries. It has resulted in poor
part quality and dimension, as well as the increase in lead
time and the associated cost. This paper proposed a DFE
based springback compensation strategy which uses an
undercut detection and avoidance as the primary criteria
during springback compensation processes. The springback
compensation scheme combines both CAD and CAE
methodology. The implementation of such strategy is
demonstrated using simple U-Channel and automotive
structural rail. The springback results are encouraging after
the implementation of the springback compensation
processing.

1.

7.

14. Liu, S.-D., Jiang, S., Garnett, M. Experimental and

Numerical Studies of Multiple Bending-Unbending
Springback Process Proc. IDDRG 2000 21ST
Biennial Congress, Ann Arbor, Michigan, USA, June
2000, pp. 203-208 (2000)
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Rajgopal, J. Analysis of Springback Using
Simulation and Experimental Design, NAMRI XXIX
May 22-25 2001 Technical Paper #MF01-248, pp. 1-8
(2001)
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Lum, L., and Lin, T-L Use of A Coupled ExplicitImplict Solver for Calculating Springback in
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18. Li zhang, Jin Wu, Dajun Zhou A New Concept on

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19. L. Wu, C. Du, L. Zhang, Iterative FEM Die Surface

Design to Compensate for Springback in Sheet Metal
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Correspondence:
Chin Chun Chen
Engineering Technology Associates, Inc.
1133 E Maple Rd. Suite 200
Troy, MI 48083
U.S.A
Tel : +1-248-729-3010
Fax : +1-248-729-3020
e-mail : ccchen@[Link]

321