Multi-Stage Forming Process Design through an Innovative, Iterative Full-Cycle Simulation with Automatic Springback Compensation for an Aluminum Hood Outer Panel

Abstract:

In the highly competitive situation of die-making, the importance of improving die production process efficiency is highlighted. However, complex sheet metal forming processes often encounter springback issues, which can impact dimensional accuracy and increase die tryout iterations. To address this challenge, this research develops the so called “full-cycle simulation” by which multi-stage forming process simulation is iteratively performed along with the JSTAMP’s auto-compensate functionality to enhance the die design performance. The innovative simulation technique is applied to perform the forming process simulation of an automobile hood outer panel made from the AA6000-IH-E aluminum alloy. The Hill’48 yield criterion is employed to accurately capture the anisotropic deformation behavior of the material. Two full-cycle simulations are conducted under the same material and boundary conditions but different die design concepts. The results demonstrate significant improvement in the draw-in profile, sheet thinning distribution and springback reduction, compared to any straightforward forming process simulation. The model, incorporating the lighter die design concept, outperforms the other model in all aspects. It is therefore put into practice. An accurate physical hood outer panel is eventually realized.

• Periodical: Materials Science Forum (Volume 1177)
• Pages: 11-18
• DOI: https://doi.org/10.4028/p-JxmX2T
• Online since: February 2026
• Authors: Jaruek Saengpetch, Sansot Panich, Kositpipat Suwannarod, Komkamol Chongbunwattana*
• Keywords: AA6000-IH-E Aluminum Alloy Sheet, Automatic Springback Compensation, Full-Cycle Simulation, Hill’48 Anisotropic Yield Criterion, Hood Outer Panel

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