Prediction of springback and tool surface modification technology for age forming of integral panel

Age forming technique has been developed to manufacture integral wing-skin panel components. A method of accurately predicting springback and modifying tool surface to eliminate the effect of the springback on forming precision should be developed, since huge amount of springback is a characteristic of this forming technology. This article uses finite element method (FEM) to analyze the age forming process of grid-type high flange integral panels, and test results show that FEM analysis results are reliable. Based on the FEM prediction of springback, a tool surface modification algorithm is developed for the age forming of integral aluminum panels. This algorithm is used in tool surface modification for the age forming of a complex high flange integral panel part. After 9 iterations, the maximal shape error of the panel part is reduced to below 0.4 mm. Its advantages of high precision and fast convergence rate have been confirmed.