Compressive stress forming systems and methods

A system for forming a metallic part, the system comprising:

• one or more hardware processors configured to determine, based on electronic modelling prior to the forming, one or more target locations in the metallic part for excess material, the excess material in the one or more target locations configured to decrease residual stress in the metallic part after the forming;
• and
• a forming tool comprising:
• one or more contacts configured to contact the metallic part for the forming at one or more contact locations away from as-cut end surfaces of the metallic part, such that the as-cut end surfaces are unconstrained during the forming;
• and
• one or more dies configured to cause, based on the one or more contact locations and the excess material at the one or more target locations, the excess material to flow in one or more specific directions during the forming to decrease the residual stress in the metallic part and reduce springback behavior in the metallic part after the forming;
• wherein the one or more dies are further configured to, before the forming, pre-form the metallic part so the metallic part includes the excess material at the one or more target locations.