Systems and methods for spingback compensation in bend forming processes

A method of bending a material to a target resultant bending parameter using a bend forming tool, the method comprising:

• receiving, via at least one processor, values for parameters of properties of the material and of a bending process to be performed by the bend forming tool;
• retrieving, via the at least one processor, a calibration curve relating input bending parameter and resultant bending parameter based on the values from a database of calibration curves, wherein the calibration curve is configured to compensate for differences between an input bending parameters and resultant bending parameters as a result of springback of the material, after bending of the material, due to a material properties of the material;
• determining, via the at least one processor, a first springback compensated input bending parameter based on the target resultant bending parameter using the calibration curve by calculating a difference between the target resultant bending parameter and a calibration curve springback compensated input bending parameter that corresponds to the target resultant bending parameter according to the calibration curve and adding a fraction of the difference to the calibration curve springback compensated input bending parameter to obtain the first springback compensated input bending parameter;
• inputting the first springback compensated input bending parameter to the bend forming tool;
• in a first step of bending the material, bending the material to the first springback compensated input bending parameter by applying the bending process using the bend forming tool and measuring a first measured resultant bending parameter of a bend created by the first step of bending the material after allowing springback of the material;
• determining, via the at least one processor, a deviation between the first measured resultant bending parameter and an expected resultant bending parameter that corresponds to the first springback compensated input bending parameter according to the calibration curve;
• offsetting the calibration curve based on the deviation to provide an offset calibration curve;
• determining, via the at least one processor, a second springback compensated input bending parameter based on the target resultant bending parameter using the offset calibration curve;
• inputting the second springback compensated input bending parameter to the bend forming tool;
• and
• in a second step of bending the material, bending the material to the second springback compensated input bending parameter by applying the bending process using the bend forming tool.