Abstract: Age forming is one of the main forming technics to manufacture integral wing-skin panel. Because of the huge spring-back in the process, it is needed to modify the tool surface to eliminate the effect of the spring-back on forming precision. So an effective method combining the finite element simulation and physical experiments is put forward, which is based on the“frequency domain” revision arithmetic based on experiment iteration. As an example, aluminum alloy 2124, the panels’ contour surface in theory is set as the form of the initial tool surface to iterate simulation spring-back compensation on the typical panel, and after compensation for 6 times, the error of part formation decreases to 0.47 mm. Then the tool surface gotten by iteration is taken to test and it is turned out that the parts’ error of this tool surface is 0.63 mm, beyond the requirement, 0.5 mm. Hence it is still necessary to modify the tool surface formed by age forming by using the “frequency domain” revision arithmetic based on experiment iteration. The error of the tool surface after revision for 2 times is 0.484 mm; it satisfies the application requirement. And this result shows that this method is practical.

Key words: Age forming, Finite element method, Frequency domain compensation, Spring-back compensation, Tool surface