The process for manufacturing automotive aluminum profiles is a multi-stage process, which includes porthole die extrusion, aging treatment, bending, and electrophoretic painting. Prediction and reduction of springback are essential in quality control of bent profiles. However, existing researches related to springback issues were mainly focused on bending process stage. This study aimed to investigate the springback behaviors of extruded aluminum profile during the whole manufacturing process by numerical simulations with experimental validations. Formation mechanism and rule of springback for aluminum profile at different process stages were revealed. The optimum process route for manufacturing bent aluminum profiles was proposed. The research results reveal that compared with the transient bending region, the springback of aluminum profile during bending process induced by the finished bending region and two straight regions is relatively small. Springback angle increases with increasing bending angle and aging time. After bending tools unloading, the stresses of the two straight zones are almost completely relaxed. However, large residual tensile and compressive stresses exist in the material adjacent to the neutral layer of aluminum profile in transient and finished bending regions. Consequently, residual stress relaxation causes additional springback of bent profiles during subsequent heat treatment processes. The additional springback angle shows linear correlation with bending angle and parabola correlation with aging time. The total springback angle is minimum for process route 3 that extruded profile is firstly bent to required shape, then treated by artificial aging and finally treated by electrophoretic painting.

汽车铝型材的制造过程是一个多阶段过程，包括舷窗模具挤压，时效处理，弯曲和电泳涂漆。预测和减少回弹对于弯曲型材的质量控制至关重要。然而，与回弹问题相关的现有研究主要集中在弯曲过程阶段。这项研究旨在通过数值模拟和实验验证来研究挤压铝型材在整个制造过程中的回弹行为。揭示了铝型材在不同工艺阶段的形成机理和回弹规律。提出了制造弯曲铝型材的最佳工艺路线。研究结果表明，与瞬态弯曲区域相比，最终弯曲区域和两个直线区域引起的弯曲过程中铝型材的回弹相对较小。回弹角随弯曲角和时效时间的增加而增加。弯曲工具卸载后，两个笔直区域的应力几乎完全松弛。但是，在瞬态和最终弯曲区域中，与铝型材的中性层相邻的材料中存在较大的残余拉伸应力和压缩应力。因此，残余应力松弛会在随后的热处理过程中引起弯曲轮廓的额外回弹。附加的回弹角与弯曲角呈线性关系，抛物线与老化时间呈线性关系。首先将挤压型材弯曲成所需形状的工艺路线3的总回弹角最小，