Numerical modeling and simulation of

bulge formation in
V-Bending of Sheet Metal
Final Review Presentation
Adhokshaj Bellurkar (ME07B066)
Guide- Prof. N Ramesh Babu,
Manufacturing Engineering Section,
IIT Madras
INTRODUCTION
Sheet Metal Bending is a plastic deformation process
where blank is deformed between tools (punch and die) to
obtain the desired final configuration.
It is widely used in automobile and aerospace industries.
Shape of the bent piece depends on:
Shape, dimension of punch and die
Contact friction condition
Material properties
Thickness of sheet
Punch velocity
Issues of concern:
Spring-back
Thinning of sheet along the bend line
Lateral bulging
Curving along the bend line

Figure 1: Press brake with (1)
Punch, (2) Die and (3) Blank
LITERATURE SURVEY
Source Content
Schroeder (1943)
An understanding of the mechanics of sheet metal
bending
Oh and Kobayashi
(1978)
Compared rigid-plastic material model to elastic-
plastic material model while applying FEM to sheet
metal bending.
Tan and Gebhardt (1980)
Showed that analytical calculations of spring-back are
inaccurate due to assumptions of circular bent portion,
central neutral-axis, amplifying the need for FEM
Nilsson et.al (1995)
Showed that FEM can be used to predict spring-back
offline by comparing results with experiments. True
stress-strain curve was used as material description
Singh et. Al (2002)
Analyzed the influence of tool geometry on springback
in air bending using FEM
Chan et al (2003)
Used FEM to study the effect of punch radius and
angle on spring-back in V-bending. Strain hardening
model used to describe material properties.
SUMMARY OF LITERATURE
Assumptions of plane strain and no thinning of bend line
make analytical formulations unsuitable for analysing
lateral deformation
Analytical and numerical models have been developed to
study springback but lateral deformation has been
uninvestigated.
Sheet metal bending can be modelled using FEM without
making aforementioned assumptions. Hence, FEM is a
more accurate way of describing the sheet metal bending
process.
Most existing Finite Element Models are in 2-D with plane
strain assumption but modelling in 3-D is essential to
visualize bulge formation along the bend line
Work done last year concluded that details such as friction
and planar anisotropy of material with respect to rolling
direction need to be incorporated for better results.

PROBLEM DEFINITION,
OBJECTIVES
PROBLEM DEFINITION
During the sheet metal bending operation, a bulge at the inner
edges and a contraction at the outer edges along the bend line is
observed.
Poses problems during assembly.
Automation of the sheet metal bending, calls for a more
sophisticated approach to the problem.
OBJECTIVES of the current work:
1. To develop a 3-dimensional FE model for predicting the
bulge formation in a sheet metal whose thickness ranges
from 1mm to 10mm.
2. To validate the model with experimental results.
3. To study the effect of variation of punch velocity on bulge
height.
Figure 2: Physical location of
bulge
SCOPE OF THE PROBLEM
The 3d FE model was used to analyse the bending process in
sheets ranging from 1mm to 10mm in thickness at bend angles of
90 , 120, 150
The bulge profiles obtained from the model were experimentally
validated.
The influence of planar anisotropy, v-width of the die, bend angle
and punch velocity on the lateral bulge has been observed and the
variation of punch force during the punch travel has been studied.
SCOPE OF ANALYSIS
Materials Mild steel
Bend Angles 90

, 120

, 150


Thicknesses 1mm, 1.6mm, 2.5mm, 3mm, 4mm, 6mm,
8mm, 10mm
Process Parameters Punch Velocity, Planar Anisotropy, Reaction
Force
METHODOLOGY





MODELLING
Suitable assumptions are made forming the basis of
the model.
Material stress-strain data is obtained by tensile tests
on MTS UTM 810 machine and is converted to true
stress-strain plots
Process modelled in Abaqus-V6.10 by 1. Defining
punch and die geometry, 2. Entering the material data,
3. Modelling and meshing the blank, 4. Assembling the
setup and entering process parameters
VALIDATION
Sheet metal bending is done on Amada HDS NT 5020
press brake for all the cases simulated
Lateral deformation is measured using a profile
projector and bulge profile plotted. Simulated and
experimental profiles are compared to validate the
model
ANALYSIS
Bulge profile is obtained from the deformed blank by
plotting the displacement node-by-node.
Neutral axis position and reaction force can be
observed from node output parameters
Punch velocity varied by changing punch travel time
MODELLING IN ABAQUS
Modelling Validation Analysis
SHEET METAL BENDING
There are various types of sheet metal bending viz air bending,
coining etc.
The process taking place is press brakes is air bending.
In air bending, the blank is located between punch and die and sheet
is bent by the downward motion of the punch.
Bend angle is determined by the downward displacement of the
punch.


ASSUMPTIONS:
1. Punch velocity is uniform
2. Process is quasi-static
3. Punch and die are rigid,
blank is deformable.
4. Retracting the punch has
no effect on bulge


Figure 3: Animated diagram of sheet metal bending
MODELLING IN ABAQUS
Modelling Validation Analysis
STEPS INVOLVED IN MODELLING
1. Modelling die and punch geometry
2. Entering material data for the sheet corresponding to the
chosen material model
3. Assembling the setup and establishing contact between
interacting surfaces.
4. Meshing the sheet metal
5. Defining initial and boundary conditions
6. Requesting output for desired variables and submitting the
model for simulation

MODELLING IN ABAQUS/CAE
Modelling Validation Analysis
1. Die- Punch Setup
Punch tip radius, V-angle, die width influence geometry of work
piece
Geometry modelled exactly as was used for experiments
Profiles of punch and die were drawn using coordinate data
from press brake
2D profiles were extruded to generate 3D parts
Both punch and die assumed to be analytically rigid bodies to
save computational cost














Figure 4: 3D models of punch (left) and die (center) for 6mm sheet with profile of the die (right)
MODELLING IN ABAQUS/CAE
Modelling Validation Analysis
2. Material Model
Material modelled using true stress-strain data obtained from
tensile tests
Plasticity data provided in the form of discrete points on true
stress-strain curve
Anisotropy defined using anisotropic creep ratios as defined in
Hills potential function
F, G, H, L, M, and N are constants obtained from plastic strain
ratio r.
Where,

Plastic strain ratios at different orientations
with respect to rolling left define the
anisotropic creep ratio R.


These values are entered in material module of Abaqus along
with the Youngs modulus, Poisson's ratio and plasticity data.







Figure 5: Tensile testing
MODELLING IN ABAQUS/CAE
Modelling Validation Analysis
3. Contact Properties and
BC
Two contact interactions are
defined; punch-blank top and
die-blank bottom.
Coeff. of friction =0.25
between blank and die, while
punch-blank contact
frictionless






4. Meshing the blank
Meshed with solid continuum
C3D8R 8-noded elements
Divided into coarse and fine
regions (element size = 0.002
and .001)
Reduced integration used to
prevent shear locking




Figure 6: Final assembly of the components before
simulation
MODELLING IN ABAQUS/CAE
Modelling Validation Analysis
5. Initial and boundary conditions
The process is initialized from the first contact between the
punch and blank
It is assumed that die and punch are completely constrained
but for downward motion of punch.
6. Entering process parameters and requesting output
Output for displacement, rotational displacement and reaction
force on punch is requested.
Process parameters for each case are entered and the model
can then be submitted for analysis.












Thickness (mm) Bend Angle () Punch
Displacement, D1
(mm)
Time taken (s)
4 90 7.45 7
120 12.045 4.84
150 16.071 3
Table 1: Process parameters for bending 4mm mild steel
sheet
VALIDATION OF THE MODEL
Modelling Validation Analysis
Experimental
Procedure for
Validation of
Model
1. Laser cutting operation on
Amada Quattro used to cut
blanks for bending and tensile
test specimens
2. Bending performed on Amada HDS
5020NT for all the cases simulated
3. Profile Projector used for
measuring lateral bulge
4. Profile traced onto a graph sheet
RESULTS CASE 1: 1mm sheet
(a) (b)
(c)
V width 8 mm
Punch tip radius 0.6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 1.89 1.37
120 3.04 1.44
150 4.05 1.68
1mm sheet bent at (a) 90
o
, (b) 120
o

and (c) 150
o
with process
parameters
RESULTS CASE 2: 1.6mm sheet
(a) (b)
(c)
V width 10 mm
Punch tip radius 0.6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 2.66 1.1
120 3.68 1.1
150 4.67 1.2
1.6mm sheet bent at (a) 90
o
, (b)
120
o
and (c) 150
o
with process
parameters
RESULTS CASE 3: 2.5mm sheet
(a) (b)
(c)
V width 16 mm
Punch tip radius 0.6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 4.55 4.2
120 7.50 2.7
150 8.85 1.5
2.5mm sheet bent at (a) 90
o
, (b)
120
o
and (c) 150
o
with process
parameters
RESULTS CASE 4: 3mm sheet
(b) (c)
V width 20 mm
Punch tip radius 0.6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 5.43 4.5
120 8.31 3.0
150 10.82 1.75
3mm sheet bent at (b) 120
o
and (c)
150
o
with process parameters
RESULTS CASE 5: 4mm sheet
(a) (b)
(c)
V width 32 mm
Punch tip radius 3 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 7.45 7
120 12.045 4.84
150 16.071 3
4mm sheet bent at (a) 90
o
, (b) 120
o

and (c) 150
o
with process
parameters
RESULTS CASE 6: 6mm sheet
(a) (b)
(c)
V width 50 mm
Punch tip radius 6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 10.065 9.65
120 14.217 7
150 18.134 4.05
6mm sheet bent at (a) 90
o
, (b) 120
o

and (c) 150
o
with process
parameters
RESULTS CASE 7: 8mm sheet
(a) (b)
(c)
V width 80 mm
Punch tip radius 6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90
16.858
12
120
28.936
9
150
39.006
5
8mm sheet bent at (a) 90
o
, (b) 120
o

and (c) 150
o
with process
parameters
RESULTS CASE 8: 10mm sheet
(a) (b)
(c)
V width 50 mm
Punch tip radius 6 mm
Bend Angle
()
Punch Displacement
(mm)
Time taken (s)
90 1.89 1.37
120 3.04 1.44
150 4.05 1.68
10mm sheet bent at (a) 90
o
, (b)
120
o
and (c) 150
o
with process
parameters
RESULTS AND DISCUSSION
Modelling Validation Analysis
Effect of punch velocity on extent of bulge height was studied
by varying process conditions for 1.6mm, 4mm and 8mm sheets
Figure 7: Bulge height variation with
punch velocity
Figure 8: Normalized bulge height trend
vs punch velocity
A definite increase in bulge height with increasing punch velocity
was observed.
*The solution diverged after reducing punch velocity below a
critical value.
0.358
0.36
0.362
0.364
0.366
0.368
0.37
0.372
0.374
0.8 0.9 1 1.1
B
u
l
g
e

H
e
i
g
h
t

(
m
m
)

Time taken for punch travel (relative)
Bulge Height (mm) vs Punch Velocity
0.97
0.98
0.99
1
1.01
1.02
1.03
1.04
0.9 1 1.1 1.25
Relative velocity
Bulge Height Trend
8mm 4mm 1.6mm
RESULTS: Influence of
anisotropy
Modelling Validation Analysis
Influence of anisotropy on the accuracy of the solution was
studied.
Figure 9: Increase in accuracy with
Inclusion of anisotropy for 8mm sheet
Figure 10: Increase in accuracy with
Inclusion of anisotropy for 1.6mm sheet

Inclusion of anisotropy helps model the process more accurately
and hence results closely matched profiles.
RESULTS AND DISCUSSION
Modelling Validation Analysis
Reaction force variation
Variation of reaction force during punch travel was studied for
different thicknesses
Figure 11: Variation in reaction
force for 1.6 mm sheet
Figure 12: Variation of reaction force for
8mm sheet
Reaction force was observed to increase with the punch travel
albeit in a non linear fashion. The magnitude of maximum force
was found to increase with increasing thickness.
RESULTS AND DISCUSSION
Modelling Validation Analysis
Existence of neutral axis
Figure 13: Bulge height vs distance along
thickness
-1.50
-1.00
-0.50
0.00
0.50
1.00
1.50
2.00
0 1 2 3 4 5 6 7 8
B
u
l
g
e

H
e
i
g
h
t

(
m
m
)

Distance from the top surface (mm)
Bulge Height (8mm at 90 deg)
-0.60
-0.40
-0.20
0.00
0.20
0.40
0.60
0 1 2 3 4 5 6 7 8
B
u
l
g
e

H
e
i
g
h
t

(
m
m
)

Distance from the top surface (mm)
Bulge Height (8mm at 150 deg)
In sheet metal bending, bulge is observed on
the inner surface and a contraction on the
outer surface.
At a certain thickness, where no bulge or
contraction is observed, is called Neutral
Axis.
RESULTS AND DISCUSSION
Modelling Validation Analysis
59.0
86.3
80.6
92.7
68.0
94.9
87.0
92.3
99
91
50.0
60.0
70.0
80.0
90.0
100.0
1.6 2.5 3 4 6 8 10
Average Accuracy (%) Accuracy with anisotropy (%)
ACCURACY:
Figure on the left shows
the accuracy of the
model for various sheet
thicknesses with/without
anisotropy
SHIFTING OF NEUTRAL
AXIS:
The figure on the right shows the
change in position of the neutral
axis over different bend angles
for a particular sheet thickness
CONCLUSIONS
The FE model was able to predict lateral deformation for sheet
thicknesses in the range of 1mm to 10mm
The accuracy of the model was within 20% for most of the cases.
Accuracy increased considerably after inclusion of anisotropy in the
model.
Punch velocity was identified as a critical parameter in the bending
process and a variation of 10% in punch velocity resulted in 1-4%
variation in bulge height.
The output of model was used to study the variation of bulge across
the thickness of the sheet and to establish the position of neutral
axis. Neutral axis shifted towards the inner surface as the extent of
deformation increased. This is in accordance with the existing
models used to identify neutral axis position.
Variation of reaction force with the punch travel was also studied.
And the magnitude of the reaction force increased with the increase
in deformation as well sheet thickness.

FURTHER WORK AND
ACKOWLEDGEMENTS
FURTHER WORK
This model can be extended to other materials such as aluminium
and stainless steel and the effect of material properties on extent of
bulge can be investigated.
Using a script to run the simulation for exhaustive number of cases,
a database can be created predicting bulge for desired sheet
thickness at any unknown angle.
Effect of bending a sheet metal on its material properties needs to
be investigated.

ACKNOWLEDGEMENTS
A special word of gratitude for Mr. Jackson and Mr. Ravindran from
Amada, India for their timely inputs and suggestions which have
guided this work in the right direction.



REFERENCES
Kalpakjian S. and Schmid S., Manufacturing Engineering
and Technology, Addison-Wesley, Reading MA, 1998
Banabic D, Sheet Metal Forming Process: Constitutive
Modelling and Numerical Simulation, 2011
Popov E. P., Bakht M. K. and Yaghmai A., Analysis of
Elastic-plastic Circular Plates, J. Engg. Mech. Dip. Proc.
ASCE, 1967
Chan W.M., Chew H.I., Lee H., Cheok B., Finite element
analysis of spring-back of V-bending sheet metal forming
processes, J. Mat. Proc. Tech, Vol. 148, pp. 1524 (2004)
Panthi S.K., Ramakrishnan N., Goel M.D., Finite Element
Analysis of sheet metal bending process to predict the
Spring-back, Materials and Design, Vol. 31, pp. 657662
(2010)
ASTM Standard for Anisotropy Measurement E517-00
Abaqus V6.10-1 Users Manual