A global springback compensation method for manufacturing metallic seal ring with complex cross-section and submillimeter precision

The fabrication of complex thin-walled components with irregular cross-sectional geometries often necessitates multi-pass forming processes. The springback phenomena at the microscale level contribute significantly difficulty to the precise control of geometrical accuracy for such components. To achieve submillimeter precision control of micro features in metal seal rings, this research proposed a global springback compensation method to facilitate the attainment of the optimized surfaces of dies. Through the analysis of changes in cross-sectional shape, stress distribution and bending moment in the multiple stages, several partition points were set up to divide the cross-section into four zones. For a partitional control of the manufactured surface, the compensation magnitudes for each segment are determined by iteratively refining the compensation factors using the secant method. The iteration of compensation factors is based on the deviation of dimensions measured by finite element simulation, which greatly saves experimental costs. The experimental results indicate that the predictive dimensional alterations by the global compensation agree with the experimental ones exhibiting a maximum error of less than 3 %. Furthermore, the springback behavior during the unloading and trimming stages coupling caused a dimensional error of 14.9 % for the wave width and 8.3 % for the peak width. Following the application of coupled compensation through two iterations, a distinct decrease in the relative average errors of springback values for both part width and peak width, achieving reductions to 2.4 % and 0.6 %, respectively. Compared to the traditional single springback compensation technique, the global compensation strategy effectively mitigates the out-of-tolerance issues induced by the trimming process.