Systematic investigation of geometrical parameters' influence on the appearance of surface deflections in sheet metal forming

Surface deflections occur during springback, which follows deep drawing. They highly affect the visual appearance of outer skin components and are, therefore, undesirable. In this work, the influence of the part geometry on the shaping of surface deflections is investigated. The geometrical parameters of an exemplary component are varied and existing surface deflections are detected. For this, a component consisting of a multiple curved surface with an inserted door handle hollow is used, and AA6016, with a sheet thickness of 1.0 mm, as well as DC06, with a sheet thickness of 0.7 mm, are chosen. After the simulations are performed in AutoForm plus R6 ^TM , a virtual stone, Three-Point Gauging and the analysis of curvatures of the part before and after springback are used to detect surface deflections.