Optimization of blank dimensions to reduce springback in the flexforming process

In sheet metal forming operations, springback of the part during unloading largely determines whether the part conforms to the design dimensions and tolerances. Finite element simulations were performed in order to study the interrelationship of the blank dimensions and interface conditions on the springback for an axisymmetric conical part manufactured by flexforming. Sensitivity analysis done using the finite element method (FEM) demonstrated that the magnitude of springback and the overall dimensional quality are highly influenced by the initial dimensions of the blank. A conventional optimization method combined with FEM was used to obtain optimum blank dimensions that can reduce springback.