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Abstract
Bending has significant importance in the sheet metal product industry. Moreover, the springback of sheet metal should be taken into consideration
in order to produce bent sheet metal parts within acceptable tolerance limits and to solve geometrical variation for the control of the manufacturing
process. Nowadays, the importance of this problem increases because of the use of sheet-metal parts with high mechanical characteristics (high
strength low alloy steel). This work describes robust methods of predicting springback of parts in 3D modelling subjected to bending and unbending
deformations. Also the effects of tool geometry in the final shape after springback are discussed. The first part of this paper presents the laboratory
experiments in wiping die bending, in which the influence of process variables, such as die shoulder radius, punch-die clearance, punch nose radius
and materials properties are discussed. The second part summarises the finite element analysis by using ABAQUS software and compares these
results with some experimental data. The final results of the FEM simulation are in good agreement with the experimental ones. An optimisation
methodology based on the use of experimental design method and response surface technique is proposed in the third part of this paper. This makes
it possible to obtain the optimum values of clearance between the punch and the die and the optimum die radius, which can reduce the springback
without cracking and damage of product.
2005 Elsevier B.V. All rights reserved.
Keywords: Sheet metals; Wiping die bending; Springback; FEM simulation; Optimisation; Experimental design; Response surface technique; Damage
0924-0136/$ see front matter 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2005.11.009
102 R. Bahloul et al. / Journal of Materials Processing Technology 173 (2006) 101110
Fig. 1. The process sequence photographed during the wiping die bending experiments of high strength low alloyed steel (S500MC). (a) Initial position, (b)
intermediate phase, (c) Springback.
f = 0, (12) Fig. 2. Initial (a) and final (b) steps of bending tests of considered specimens.
Fig. 3. Numerical approach: various simulation sequences of wiping die bending. Appearance of springback phenomenon.
The value of coefficient of friction between the punch and the larger deformation energy needed to bend the sheet to a smaller
part surface is equal to 0.09 and the contact at the interfaces of radius.
die, sheet and blank holder is modelled by a value of 0.15. The The results obtained by two approaches make it possible to
goal of this application is to show the aptitude of this model to give the relative variation of springback compared to the exper-
predict the springback and to study the influence of certain geo- iment and expressed by: (%) = [( exp num )/ exp ] 100.
metrical parameters related to the process on this phenomenon. They are 9% and 10.2%, respectively for die radii of 1 and 6 mm.
This makes it possible to know on which technological param- Consequently, the springback evolution curve determined by the
eters is necessary it to act in order to increase or reduce the numerical approach is thus in good agreement with the experi-
springback. mental one.
In case of small die radius equal to 1 mm, the springback is
5.1. Inuence of die radius on springback not significant any more because there is an almost total rupture
of specimens by cracking as shown in Fig. 5. The section of
Fig. 4 shows the effect die radius Rd on the evolution of resistant material is very decreased, which explains the reduction
springback after bending. Many experiments were carried out on of springback. So it can be concluded that smaller the die radius,
specimens cut in transversal direction (90 -direction), by main- the less will be the springback.
taining punch-die clearance equal to the thickness. The treatment
of experimental and numerical results leads to a better com- 5.2. Inuence of punch-blank clearance on springback
prehension of mechanical behaviour and geometrical quality of
specimens after bending. It can be noted on Fig. 4 that a large die For the same test conditions, experiments have been con-
radius favours a significant increase of the final bending angle ducted on specimens by always keeping the same cutting direc-
compared to the desired one. The loading which the sheet under- tion, but by varying sheet-punch clearance C in the interval
goes on the bent zone strongly affects its geometrical properties [0.6, 0.6] mm with uniform increment of 0.2 mm. A total
because the transformations of the microstructure during bend- 35 experiments was carried out which include five tests for
ing operation depends on the conditions retained. For vertical each clearances. Fig. 6 shows the evolution of springback
bending force applied by the punch, a smaller die corner radius predicted by numerical and experimental approach at vari-
rquires more deformation force. This can be explained by the ous clearances. More the distance between punch and blank,
more the springback after bending which is confirmed and val-
idated by these experiments. A smaller clearance produces a
larger maximum strain in sheet metal part, which decreases the
Table 2
Springback values in (degrees) determined experimentally for various die radii
and clearances
Rd (mm) Clearance (mm)
6. Optimisation problem
Fig. 6. Effect of punch-blank clearance C on springback angle in case of constant A set of data points where the response y is calculated or
die radius. measured is required to obtain the response surface. It is desir-
able to select a set of data points that maximises accuracy of the
approximation for given number of data points. The process of
relative influence of elastic deformation. The curves deduced selecting a set of the data points is known as design of experi-
from the two approaches have the same trend. They evolve sim- ments (DOE) [16]. The main objective of this investigation was
ilarly in a non-linear way. to study the effects of interaction of tools geometrical param-
As shown in Fig. 6, little variation of springback occurs eters in sheet metal forming process by wiping die bending in
for negative clearances varying between 0.6 and 0.2 mm in order to optimise the process. Experiments and simulations were
which the conditions of friction between the punch and sheet are conducted for an extensive combination of die radius values Rd
very severe. For the same die radius, it seems that the variation and punch-blank clearance values C. A full factorial design of
of the bending angle is marked when the ratio t/(t + C) is lower tow factors is carried out by varying the design parameters and
than 1. t and C represent the sheet thickness and the clearance, analysing the response related to the springback. The experi-
respectively. A relative variation of springback compared to the mental and numerical procedure had needed 28 cases of tests
experiment is equal to 22% can be noted for highest clearance in press tools and numerical simulation, respectively: four die
value. For negative or zero clearances the friction will be one radius [1, 2, 4, 6] mm seven clearance values [0.6, 0.4,
of the causes of increase of loads allowing to a marked stress 0.2, 0, 0.2, 0.4, 0.6] mm. The experimental and numerical
state especially at the interface between punch and blank. Fig. 7 response of springback according to these process parameters
shows the state of bent specimens subjected to friction gener- are reported in Tables 2 and 3 in the form of experiment matrix.
ated by punch. For die radius of 1 mm, Fig. 7a corresponds to
positive clearance C of 0.6 mm and Fig. 7b represents a bending 6.2. Response surface methodology
test with negative clearance of 0.6 mm.
Especially, for specimens with oblong hole, localisation 6.2.1. Curve tting
zones of damage and cracks are detected at the rounded-offs Response surface methodology is applied to obtain an
of oblong hole. The same phenomenon was observed for other approximation to a response function in terms of predictor vari-
die radii. On the marked zone there will be significant reduction ables. The response model is generally written as:
of the thickness of specimen and the appearance of cracks, as
result of punch die clearance lower than the thickness. y = F (x1 , x2 , . . . , xn ) + , (16)
Fig. 7. Crack formation in the bending zone and marks of friction for Rd = 1 mm. (a) C = 0.6 mm. (b) C = 0.6 mm. (c) Damage contour at the bent zone.
R. Bahloul et al. / Journal of Materials Processing Technology 173 (2006) 101110 107
For ease of notation, let x3 = x12 , x4 = x22 , x5 = x1 x2 . Thereby, In the previous expression y represents the response according
the equation becomes: to the variables xi (i = 1, . . ., n)(parameters of the operation) and
is a term representing the error compared to the exact solution.
y = 0 + 1 x1 + 2 x2 + 3 x3 + 4 x4 + 5 x5 . (19) Here it has been found that the third order approximation can
simply present the tendency of observation surface. Contrary it
The unknown coefficients i (i = 0, 1, . . ., 5) in Eq. (18) are
has been noted that the fourth order polynomial approximation
estimated by a linear multiple regression. The linear multiple
was shown to be reliable and sufficient to fit the experimental and
regression model is rewritten in matrix form as:
numerical data and to represent the evolution of the springback.
Y = X + (20) It can be written in the following form:
n
n
n
n
where y = 0 + i x i + ii xi2 + ij xi xj + ii xi3
y1 1 x11 x12 x1k i=1 i=1 i<j i=1
y2 1 x x2k n n n
21 x22
Y= , X= ..
.. , + ij xi2 xj + ii xi4 + ij xi3 xj
...
.
.. .. ..
. .
. . i=1,i=j i=1 i=1,i=j
yn 1 xn1 xn2 xnh n 2
+ x + (26)
i=1 i
1 1
2
2 Optimisation is carried out in order to determine the optimal
= . , and = . (21) values of the geometrical parameters of the process, which allow
. ..
.
a minimisation of springback . The multi-objective problem can
be formulated as follows:
n n
where is the error vector. The unbiased estimator b of the Minimise Exp = f (Rp , Rd , J) (27a)
coefficient vector is obtained using the last square error method Minimise Num = f (Rp , Rd , J) (27b)
as
1 with the geometrical constraints:
b = (XT X) XT Y (22)
Rdmin Rd Rdmax (28a)
By obtaining coefficients vector b from Eq. (22), the response
surface is prepared. Jmin J Jmax (28b)
108 R. Bahloul et al. / Journal of Materials Processing Technology 173 (2006) 101110
Fig. 8. Springback results given in form of parametric curves, response surfaces and contours plots. (a1 , a2 and a3 ): experimental approach. (b1 , b2 and b3 ): results
of finite element analysis.
theoretically its not easy to make up friction model that takes into of finite element simulations of the process has been completed
account all process and environmental parameters such tempera- using commercial programs ABAQUS.
ture at interfaces, velocity, lubrication characteristics, contacting The influence of die radius and clearance on springback vari-
area and surface roughness. ation and the zone where cracks appear are compared between
Even if error between experimental and numerical results experimental and numerical approaches and sources of error
exists, it is can be judiciously considered acceptable. Coher- were discussed.
ence of springback results predicted by Finite Element analysis As a set of discussions given above, the following conclusions
and experimental data seems to be very well and reliability of have been made:
numerical model is achieved.
Springback after wiping die bending operation is heavily
8. Conclusions dependent on die corner radius. It means that large die radius
favours a significant increase of the final bending angle
In this work, examination and comprehension of final geo- compared to the desired one. In case of small die radius
metrical quality of parts after wiping die bending operation are equal to 1 mm, the springback is not significant any more
conducted by part design with oblong hole for a better investiga- because there is an almost total rupture of specimens by
tion of study of safety parts. The springback prediction has been cracking.
validated with some laboratory experiments and was performed More the distance between punch and blank, more the
on specimens of 4 mm-thickness on high strength low alloy steel evolution of springback after bending operation and con-
(HSLA). This method was applied on a specific type of flang- firmed and validated by experiments. A smaller clearance
ing in which the edge is coined at the end of the operation. The defines a larger maximum strain at the edge of sheet
parameters related to the process, the die radius Rd and sheet- metal part, which decreases the relative influence of elastic
punch clearance C were retained in adimensional form. A set deformation.
110 R. Bahloul et al. / Journal of Materials Processing Technology 173 (2006) 101110
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