Springback is a common defect caused by elastic recovery in the plastic forming process, which can cause the formed workpiece to deviate from the target shape. The purpose of this paper is to grasp the influence law of process parameters on springback deviation so as to optimize process parameters to reduce springback. Taking the Y-profile as the research object, the influence of process parameters such as horizontal bending radius, vertical bending radius, transition zone length, radius of roller dies, and wall thickness of the profile on springback deviation is discussed by numerical simulation. Additionally, the validity of the numerical simulation is verified through experiments. The springback law obtained by numerical simulation is applied to practical production, and the large-scale production of the Y-profile is realized.

In the process of flexible 3D stretch bending, the shape deviation difference between the contact zone and non-contact zone is studied. It is obvious that in the contact zone, the die regulates the deformation of the profile to make it conform to the target shape with small shape deviation; in the non-contact zone, the profile has no die restriction and deviates from the target shape with large shape deviation. When the dies are placed equidistantly along the x-axis, the shape deviation of the non-contact zone near the clamp side is greater than that near the middle of the profile. Arrange the distance between adjacent dies in equal ratio along the x-axis, so that the spacing near the clamp side is a little smaller, and the spacing near the middle of the profile is a bit larger. The difference between the shape deviation of the non-contact zone profile near the clamp side and the middle of the profile decreases, and the maximum shape deviation is reduced, which greatly improves the processing accuracy and quality. However, with the increase of the distance difference between adjacent dies, the shape deviation difference of the non-contact zone near the middle of the profile also increases greatly. Although the clamp side decreases, the maximum shape deviation has become the shape deviation of the profile in the non-contact zone near the middle of the profile.