Die design optimization on sheet metal forming with considering the phenomenon of springback to improve product quality

¹ Department of Mechanical Engineering, Faculty of Engineering, Universitas Muhammadiyah Surakarta, Jl. Ahmad Yani, Tromol Pos 1 Pabelan, Surakarta 57162, Indonesia
² Department of Mechanical Engineering, Faculty of Engineering, Universitas Batam, 29464 Batam, Indonesia

^* Corresponding author: Agung.Darmawan@ums.ac.id

Abstract

The process of sheet metal forming is one of the very important processes in manufacture of products mainly in the automotive field. In sheet metal forming, it is added a certain size at the die to tolerate a result of the elasticity restoration of material. Therefore, when the product is removed from the die then the process elastic recovery will end within the allowable tolerance size. Extra size of the die is one method to compensate for springback. The aim of this research is to optimize the die by entering a springback value in die design to improve product quality that is associated with accuracy the final size of the product. Simulation processes using AutoForm software are conducted to determine the optimal parameters to be used in the forming process. Variations the Blank Holder Force of 77 N, 97 N, and 117 N are applied to the plate material. The Blank Holder Force application higher than 97 N cannot be conducted because the Forming Limit Diagram indicates the risk of tearing. Then the Blank Holder Force of 37 N, 57 N and 77 N are selected and applied in cup drawing process. Even though a few of wrinkling are appear, however there is no significant deviation of dimension between the product and the design of cup.