Research on the factors affecting the prediction accuracy of numerical simulation on springback during rubber fluid forming

Process analysis method based on FE numerical simulation can improve the quality of rubber fluid forming (RFF) part, while the accuracy of springback prediction is the critical factor for numerical simulation of straight flanging RFF. A numerical model was established including forming and springback process for aluminum material 2B06-W30min straight flanging in RFF using PAM-STAMP 2G software as a platform. The key factors of the accuracy of springback prediction on element integration type, mesh size, thickness direction integration scheme, variability in thickness of blank, and other affecting factors were studied. The key affecting law of springback prediction and the way to improve the accuracy of springback were found according to the comparison analysis between the results of FE numerical simulation and the experiment data. It aims to control the key link of numerical simulation, to decrease the accumulated error, to increase the accuracy of FE numerical simulation of RFF and to serve as production and technical guidance.