DESIGN OF BENDING DIES FOR BRACKET REAR SPRING FRONT 2 BASED ON CAE SPRINGBACK ANALYSIS

Abstract

This study redesigned the dies bending of automotive components Bracket Rear Spring Front 2 using numerical simulation based on Computer Aided Engineering (CAE), in order to overcome the decrease in geometric precision due to the springback phenomenon. The analyzed components showed a significant decrease in accuracy, from 98.72% to 53.84%, which was identified through fixture checking measurements and 3D metrology. Simulations were performed on four bending angle variations (88.5°, 89°, 90°, and 90.92°) to evaluate final angle deviation and dimensional accuracy. The results showed that an angle of 88.5° resulted in the highest accuracy of 92.31%, with a minimum deviation to the shape of the design. Validation is carried out through comparison of the simulation results with the actual parts on the surface clearance and trimming line parameters, which shows high conformity. Statistical analysis yielded a Root Mean Square Error (RMSE) value of 0.67° and a coefficient of accuracy variation of 3.12%, indicating consistency between configurations and the effectiveness of the approach. These findings reinforce the role of CAE as a prescriptive tool in industrial anniversary redesign, particularly for older tooling that lacks technical documentation. This approach not only improves manufacturing accuracy and efficiency, but can also be replicated for tooling rehabilitation in the process of forming high-precision metals in the automotive sector.