Experimental and Numerical Prediction of Spring back in U-bending Process (original) (raw)
Related papers
Design And Analysis Of A Spring Back Effect In Sheet Metal Forming
International Journal of Research in Engineering & Advanced Technology, 2016
One of the largest challenges in manufacturing is the consistency of final products. Two basic approaches have been investigated to achieve this goal. One is to use intelligent assembly methodologies to select a suitable set of parts to be assembled which is taking advantage of tolerance stack up. The other approach aims at each individual manufacturing process module, for example sheet metal forming process. The forming of sheet metal into a desired and functional shape is a process, which requires an understanding of materials, mechanics, and manufacturing principles. The major problem in fabrication of sheet metal parts is spring back effect i.e. the elastic strain recovery in the material after the tooling is removed. Spring back control is one of the key concerns of the sheet metal forming industry. The current trial-and-error method of testing and controlling for spring back is costly, time consuming, and remains as an obstacle in achieving shorter design production cycles. The elastic spring back at the end of a bending process plays an important role in determining the quality of final product thus in practice the constitutive relation that considers the elastic and plastic parts together has to be used. The factors have a non-linear interaction with each other so it is extremely difficult to develop an analytical model for spring back control including all these factors. So approach with FEA simulations are used to confront this difficulty.
Numerical Investigation of Spring Back on Sheet Metal Bending Process
Spring back is the main defect in sheet metal bending process. The spring back of sheet metal bending, which is defined as elastic recovery of the part during un loading conditions. It should be taken in to considerations so as to produce bent sheet metal parts within acceptable quality. Spring back is affected by the factors such as; sheet thickness, tooling geometry, friction condition; material property and processing parameters. In this research the numerical investigation of Spring back on edge bending die process is done.. The numerical Analysis is done using ANSYS LS-DYNA. The influence of sheet metal thickness, sheet metal type, friction, tool radius and tool shape on spring back for Aluminium, copper, mild steel and High strength steels, sheet metal have been considered for investigations.
Spring back is the main defect in sheet metal bending process. The spring back of sheet metal bending, which is defined as elastic recovery of the part during un loading conditions. It should be taken in to considerations so as to produce bent sheet metal parts within acceptable quality. Spring back is affected by the factors such as; sheet thickness, tooling geometry, friction condition; material property and processing parameters. In this research the numerical investigation of Spring back on edge bending die process is done.. The numerical Analysis is done using ANSYS LS-DYNA. The influence of sheet metal thickness, sheet metal type, friction, tool radius and tool shape on spring back for Aluminium, copper, mild steel and High strength steels, sheet metal have been considered for investigations. Abstract-Spring back is the main defect in sheet metal bending process. The spring back of sheet metal bending, which is defined as elastic recovery of the part during un loading conditions. It should be taken in to considerations so as to produce bent sheet metal parts within acceptable quality. Spring back is affected by the factors such as; sheet thickness, tooling geometry, friction condition; material property and processing parameters. In this research the numerical investigation of Spring back on edge bending die process is done.. The numerical Analysis is done using ANSYS LS-DYNA. The influence of sheet metal thickness, sheet metal type, friction, tool radius and tool shape on spring back for Aluminium, copper, mild steel and High strength steels, sheet metal have been considered for investigations.
Effects of Process Parameters And Investigation Of Springback Using Finite Element Analysis
2014
One of the most sensitive features of sheet metal forming is the elastic recovery during unloading called springback. Sheet metals are prone to some amount of springback depending on elastic deformation. Variations in the mechanical and dimensional properties of the incoming material, lubrication and other forming process parameters are the main causes of springback variation. Accurate prediction and controlling of springback is essential in the design of tools for sheet metal forming. This paper gives the prediction of springback for U bending using FEA. In this research the material properties for IS513D are used. Sheet metal with four different thicknesses such as 0.7, 0.8, 0.9, 1.0mm are used. Also four different blankholder forces are used. The effects of these parameters on sheet metal are studied and springback is investigated. Keywords— FEA, blankholder force, sheet thickness, springback, Ubending
Finite Element Analysis of sheet metal bending process to predict the springback
Materials & Design, 2010
Springback remains a major concern in sheet metal forming process. Springback, shape discrepancy between fully loaded and unloaded configuration due to elastic recovery of material, is mainly affected by geometrical parameters, material properties of sheet and lubrication condition between the blank and the tool. A total-elastic-incremental-plastic (TEIP) algorithm, for large deformation and large rotational problems, was incorporated in indigenous Finite Element software. This software was used to predict the springback in a typical sheet metal bending process and to investigate the influence of these parameters on springback. The results of simulation are validated with own experiments and published experimental results.
The influence of process conditions on springback in bending process
-In the sheet metal forming process, the steel, in this case deep drawing quality steel DC06 exhibits springback effect, which is governed by strain recovery of material after the load removal. In this work, numerical simulation of a V-shape part bending was performed and compared with experimental data. Springback is related to many parameters like forming conditions, tool geometry and material properties such as sheet thickness, yield stress, work hardening, strain rate sensitivity and elasticity modulus. In this contribution, the influence of process conditions on springback effect of V-shaped part made of deep drawing quality steel DC06 was investigated. In the numerical simulation, two types of Yield criterion: Hill48 and Barlat were used in combination with Swift hardening model. Achieved data from numerical simulation were compared with experimental test results.
Literature Review on Analysis of Spring Back in Sheet Metal Forming Processes
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2022
The spring back is the part of sheet metal bending that is most susceptible to failure during unbounding. Elastic and plastic deformation combine to completely distort the workpiece (sheet metal) during the metalworking process. When sheet metal is being worked on, it is put under a lot of pressure, which causes plastic deformation. However, when the pressure is released, the material recovers elastically. During the entire process. small amount of reduction in the total deformation takes place So, this phenomenon. is called as spring back-the change in sheet metal's geometry. The thickness of sheet metal ranges from 0.5 mm to 6 mm. Depending on the tooling geometry, material qualities, sheet thickness, and punch and die properties, spring back can affect the completed part's dimensional accuracy. Sheet metal elements / materials / appliances made in industries such as automotive OEM and ancillaries, enclosures aircraft, heavy machinery, medical devices etc. are affected by spring back in their correctness. This review study examines various factors influencing springback in sheet metal fabrication
Study the Effects of Spring Back on Sheet Metal Bending using Mathematical Methods
Journal of Material Science & Engineering, 2017
In this study mathematical analysis of spring back was done for optimization of sheet metal bending process. The influence of sheet metal thickness, sheet metal type, friction, tool radius and tool shape on spring back for Aluminium, copper, mild steel and High strength steels, sheet metal have been used as variable to conducted this study. Since, the effects of each variable on the formation of spring back on sheet metal forming are investigated the following way. This empirical result shows that increasing sheet metal thickness from 0.8 mm to 4.5 mm the spring back is reduced 16% and 20.35%. When increasing of sheet metal strength spring back increases because spring back of the sheet should depend on the yield strength of the material. As the materials yield strength increase the spring back after unloading condition also increases. The effects of material type as shows that, using Aluminium sheet metal instead of high strength sheet metals spring back is reduced by 56.%. Also, for decreasing of the tool radius leads reducing spring back. Spring back of deferential die 12% lower than edge bending die. In addition to these, if increasing the friction coefficient from 0.01 to 0.50 the spring back also increases by 52% because of increasing of friction force and this force generates higher amount of spring back. Thus the effects of material type, tool geometry, working condition and the thickness of sheet metal types were studied and investigated. Since, ultimately utilizing and compensation of tool is considered for prevention of spring back and optimizing of sheet metal bending process as well.
2018
To reduce springback in U-shape of high strength steel sheet, the present paperproposes a new process parameter in U-bending technique. This paper aims to present the effect of clearance between die and counterpunch on springback behavior. The process in this work consists of four steps; (1) clamping of a sheet between a punch and a pressure pad, (2) bending with constant clamping force, (3) pushing-up at bottom of the part by using the pressure pad , and (4) final release tool. From the experimental results, decreasing of bending moment by bottom pushing-up resulted in the springback reduction. An appropriate of the clearance between die and pressure pad combined with bottom pushingup force can be reduced springback. Our results suggested that the Y-U model, an advanced kinematic hardening, is essential for accurate numerical simulation of springback behavior.
Investigation of springback in U shape bending with holes in component
Industrial Engineering Journal, 2018
One of the sensitive features of the sheet metal forming is the elastic recovery at the time of unloading called springback. Sheet metals are prone to some amount of springback depending on elastic deformation. Obtaining the desired size and shape of the component and also design of die and punch depends on the knowledge of the amount of spring-back. So the accurate prediction of the springback is very important. The springback is affected by the factors such as sheet thickness, material properties, tooling geometry etc. In the present paper the effect of various parameters such as sheet thickness, ratio of die radius to sheet thickness i.e. R /t ratio, strength coefficient and strain hardening exponent on springback are studied for the U shape component without holes and with holes in it.