ARCHIVES of International Scientific Journal

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Materials Science of Computational Materials Science
and Surface Engineering and Surface Engineering

2 0 0 9 Vo l u m e 1 Is s ue 3 168- 173

Interface driven optimisation of springback

in stretch bending of autobody panels
G.S. Hegde*, J. Shivaprasad, R. Sridhar
Department of Mechanical Engineering, R.V. College of Engineering,
Bangalore- 560059, India
* Corresponding author: E-mail address: [email protected]
Received in a revised form 20.12.2007

ABSTRACT

Purpose: Analytical determination of springback in the stretch bending of autobody double curved panels and
optimization of parameters like yield strength and thickness of plate, have been the prime purposes of this paper.
Design/methodology/approach: The elasto plastic behaviour governed by Hookes law and Holomanns
law, has been solved using interface theory, the original contribution of author. In the process Hegdes interface
modulus has been coined, which depends on both modulus of elasticity and the plastic coefficient.
Findings: The linearized functions of change of springback and stretch tension are solved for optimization, again
using interface theory briefed in the Appendix.
Practical implications: The published models of springback optimization being complicated, a need has been
felt to formulate computationally easy and confidently accurate model of springback determination. The theoretical
deliberations are demonstrated on materials based on the data obtained from the published references.
Originality/value: The authors are confident of the originality and do claim authentically the novelty in the
workout of the analysis. The interface theory applied at several stages in the analysis gives the optimal solutions to
variables in the hyperspace defined by a linear system with redundancy in unknown variables.
Keywords: Springback; Optimization; Elsato-plastic relation; Interface theory
Reference to this paper should be given in the following way:
G.S. Hegde, J. Shivaprasad, R. Sridhar, Interface driven optimisation of springback in stretch bending of autobody
panels, Archives of Computational Materials Science and Surface Engineering 1/3 (2009) 168-173.

ENGINEERING MATERIALS PROPERTIES

1. Introduction
1. 
Introduction strains and external deviations in the form of localized thinning of
the parts and errors in shape. Several researchers contributed
towards the simple cases of spring back due to pure bending with
In the tool design for forming operation of autobody panels
and without stretching, on the theoretical and experimental basis.
made of sheet metal one of the decisive parameters to be
The analytical predictions had been reported in [1-3]. The
considered is the spring back of the sheet. The shape of the
problems in manufacturing because of springback in high strength
formed metallic panel depends on the spring back, which is
steels, have been the recent topics of discussion in the works[4,5].
observed after removal of applied loads from the deformed sheet.
The spring back leads to curling problems, which has been dealt
The spring back is responsible for the deviation in the final
in [6]. The effect of restraining tension due to binder force on the
deformed shape from the punch shape which has the desired
control problems considering spring back had been discussed in [7].
shape of the product. The final unloaded configuration of the part
The optimum binder force estimation to increase the drawability, to
includes internal deviations in the form of residual stresses and

168 Copyright by International OCSCO World Press. All rights reserved. 2009
control the process parameters and to avoid the instability had where V e is the elastic stress, H e is the elastic strain and E is the
been demonstrated through computer aided modeling approach in modulus of elasticity. Beyond yield region, the material behaviour
the literature [8]. The binder force control and shape aspects are assumed is non- linear and this tends to obey the Holomanns law
treated separately [9] to evaluate the spring back to describe the given by,
shape perturbation in the paper [9]. Here emphasis is on the V p = K(H p)n (2)
determination of the tool shape to yield correct part shape with the where V p is the plastic stress, K is the work hardening modulus
assumption of suitable binder condition. An in-process and n is the plastic index. H p is the plastic strain. It is true that
measurement is highlighted in [10]. In the literature [11], the when the processing behavior is not clear to be elastic or plastic it
estimation of spring back by in process measurement for single is wrong to assume the summation of Equations (1) and (2). But
curved roll bending, had been demonstrated. In the works [12] the in the present case it is assumed that the forming by stretch
closed loop control philosophy was used to control the part shape bending has crossed the threshold of elasticity and processed in
by working out a transfer function relating the change in part the complete plastic state. Hence the addition of Hookes and
shape to the change in the tool shape. Holomanns Equation is justified with the existing computational
The estimation of the spring back of a double curved auto domain. The authors have checked this fact with reference to
body panel based on the elasto-plastic deformation has been the elasto-plastic analysis of pre-stressed holes. Hence from
prime objective of this paper. The complicated workout in [13] to Equations (1) and (2) the total stress can be written as
evaluate the springback is simplified with the help of interface V = EH e+ K (H p )n (3)
theory [14] which solves the elasto-plastic equation. The The Equation (3) being non linear, the solutions for H e and H p
bidirectional stresses obtained are used to calculate the plastic
in terms of knownV, E, K and n, is not simple by computational
stress and strain components. The plastic bending moment, hence
methods available. But it is made easy in the application of
obtained, aids in the calculation of the spring back and the
interface theory (see Appendix) a specialized computational tool
tensions to be created by the binders are also obtained. Further the
developed by author to handle linear system with more unknown
procedure of the parameter optimization is demonstrated which
than the number of equations at access. To obtain optimal values
also utilizes the interface theory (explained briefly in appendix) to
to H e and H p by interface theory it is imperative to arrange the
minimize the spring back under the constraint of tension force to
terms in the ascending order of their co-efficient. Since E > K for
be created by the binder. In simple terms, the interface theory
any material the Equation (3) is rearranged to
gives the optimal values to the variables in a linear equation with
redundancy in unknown variables. The material properties data of V = K (H p) n + E H e (4)
[13] have been used as reference in the numerical demonstrations The Equation (4) resembles with Equation (A1) of appendix
of the theoretical deliberations of this effort. with
The paper is organized in the following sections as, the a i = [K , E]
background justification in introduction, formulation to give xi = [(H p) n, H e] and b = V
spring back calculation, numerical demonstration in Hence from interface theory
1/ n
implementation, comparison of results in discussion and finally
the statement of the outcome in conclusion. The appendix briefly X1  
pn b V V
or p
(5)
a2 E E
gives the interface theory for reference [14]. and
Interface theory being authors original contribution helps in
e a1 b
solving the elasto-plastic stress strain relation appearing in the X 2 H 1 
computational work. To the knowledge of authors the formulation a2 a2
methodology is new and different of its kind in the mechanics of or, K V (6)
X H
e
1 
sheet metal forming. 2
E E
From the generalized Hookes law for a biaxial stress system
the relations between stresses and strains in the x and y directions
work out to be
2. Formulation
2. 
Formulation 
V 1e E H 1e  P H e2 1  P
2
  (7)
where is the Poissons ratio which is the ratio of 2 and 1, and
 
The spring back causing geometrical surface defects in double
curved autobody panels is initiated mainly because of the released 
V e2 E H e2  P H 1e 1  P
2 (8)
plastic bending moments on unloading and non-uniform But from the Equation (6) it can be confirmed that
distribution of stress during forming. For understanding the later K or simply (OV1) (9)
concept it is suggested to refer [15]. The former case is the focus H 1e E1 1  E

of this study. For the elasto-plastic analysis the following K
assumptions are to be considered as, 1. There exists plane stress 1 
where O E 1/ = Hegdes interface modulus
condition in the material so that V3 =V z= 0, and 2. The stress E
strain relation is characterized by the known conventional
linearplot in the beginning and non-linear plot beyond yield. The
and H e2 O V 2
On substitution of (9) and (10) in expressions (7) and (8)
material, within the yield region behaves linearly and obeys the
EO (11)
Hookes Law to be stated as V e
1   P V 2
2 V1
V e=EH e (1) 1 P

READING DIRECT: www.archicmsse.org 169

 G.S. Hegde, J. Shivaprasad, R. Sridhar

EO (12) L
V e
2 2
V 2  P V 1
1 P
As the elastic limit terminates at yield point, it can be reasonably
assumed as 1e = y = yield strength and hence Rp
V y A V 1  P V 2  (13) h
2 Rs
where A = EO/(1-P )
By the application of interface theory to Equation (13) and since,
A < A
h
1  P V y Vy
V 1
A
and V2 A
(14)

By substitution of solutions (14) in Equation (5) it is possible to

Fig. 1. Springback diagrams
arrive at
1

p V1n
1


1  P  1  P 2 V y


n
(15) From the mechanics of solids
H 1 2
E E O p t p

1
M 0 V ZdZ (21)

p V 2 n
1


1 P2 V
y

 n
(16)
V t
p 2

H 2 2
E E2 O
p t p p
Hence from the relations (15) and (16) the plastic stresses are and T 0 V dZ (V )t (22)

p
 
P n
K 1  P  1  P 2 V y   (17) The Equations (21) and (22) give the plastic moment and the
V1 K H1 2 tension in unit length of the panel. From relations (17), (19), (20)
E O and (21) the spring back in direction 1 is

H 2P n 
K 1 P2 V y 22

1 121  P  1  P k V y 2 
V 2p K (18)
' h1
(23)
L1
2
E O 2 E
3
tO

From relations (18), (19), (20) and (21) the spring back in the
direction 2 is
2.1. Estimationofofspring
2.1. Estimation spring back
back

' h2


22
6 1 P k V y 2  (24)
With high tensions in both directions, the neutral axis 3
tO L2
disappears from the cross section and both inner and outer surface E
of the panel deform plastically in tension which is depicted by the
stress and strain distribution which is quite evident and well The relations for tension to be applied in the two directions
established fact. With this the forming of the panel exhibits an work out to be
important phenomenon of tension controlled bending with purely
plastic section of the panel. p

k 1  P  1  P 2 V
y
t
 (25)
On unloading of the punch, there result two changes- one is
T1 2
E O
release of tension force leading to the sliding of sheet around the
punch without any shape change and the other is release of plastic
moment resulting in change of radius of curvature from punch p

k 1  P2 V
y
t
 (26)
radius Rp to sheet radius Rs. T2 2
E O
It has been shown in reference [13] that
1
'
1

1 12 M p 1  P  2
 (19)
R R p Rs Et 3
2.2. Springbackminimization
2.2. Springback minimization
However it is derived in paper [13] that the springback, h, with
fairly good approximation For a panel of known and given length 2L the spring back
1 1 2 h is expressed by the function
'h ' L (20)
'h f (V y , t ) (27)
2 R
where L is half the length of the panel in the intended direction as The linearized expression for Equation (27) is
shown by Figure 1. 'H H1 ' V y  H 2 't (28)

170 Archives of Computational Materials Science and Surface Engineering

Interface driven optimisation of springback in stretch bending of autobody panels

where
3. Implementation
3. 
Implementation
wH 6(1  P )(1  P 2 ) 2 k L12 for curvature 1
H1 3 With a purpose to demonstrate the theoretical findings from
wV y E tO
previous section, the panel with steel (FePO4) and 6016-t4-EDT,
2 2 2
or 6(1  P ) k L1 for curvature 2 having the material data given in Table 1, have been used. The
3 punch dimensions for the double curved auto panel are
E tO Rp1 = 665 mm and Rp2 = 2000 mm from reference [13] have been
wH 6(1  P )(1  P 2 ) 2 k V y L22 taken. The binder force is varied to obtain stretch tensions from 0,
H2  for curvature 1 100, 200, 300, 400 and 500 N. The spring back in both
wt 3 2
E t O dimensions are computed as listed in Table 2.
6(1  P 2 ) 2 k V y L22
or  for curvature 2 Table 1.
3 2
E t O Properties for material 1- Steel and material 2-6016-T4-EDT [13]
The tension in the panel is also expressed as a function of y and t, Sl.No t(mm) y(MPa) E(MPa) K(MPa) n
as 1 0.8 172 205000 527 0.23 0.3
2 1.2 95 70000 344 0.24 0.33
T = g (Vy, t)

The linearized Equation is Table 2.

Computed results
'T = G1 'Vy + G2 't (29) Parameters Curvature 1 Curvature 2
Material 1 Material 2 Material 1 Material 2
where p 5.868E-15 1.343E-13 2.767E-14 7.12E-13
wT k (1  P )(1  P 2 ) 2 t for curvature 1 p
(MPa) 0.281 0.28 0.401 0.418
G Mp(N-mm) 0.09 0.202 0.128 0.301
wV y E
1 2
O
2 2 Tp(N) 0.2248 0.2424 0.1024 0.3612
or (1  P ) kt for curvature 2 h(mm) 0.062 0.118 0.2663 0.5322
2
E O L(mm) 115 200
Rp(mm) 665 2000
wT k (1  P )(1  P 2 ) 2 V y for curvature 1
G
E
2
2
wt O It is evident from Table 2 that the plastic strain increases with
2 2 the length for a given material. There is appreciable change in the
(1  P ) kV y plastic stress with the curvature. For the same curvature the
or for curvature 2
2 springback is dependent on the material elastic and plastic
E O properties, never-the-less the geometric properties like thickness
also play major role in the springback calculation. Brittle
The optimization problem is
materials require higher tension and bending moment for stretch
Minimize 'H = H1 'Vy + H2 't (30) bending as they are more prone to springback effects. Larger the
Subject to G1 'Vy + G2 't = 'T curvature length more is the springback observed. The tension
where T is the parameter, which is the constraint since G2>G1 force is a direct constraint in the reduction of springback. The
By the application of interface theory materials with higher Youngs modulus, higher yield strength and
'V y
'T 't = 1  G1 'T thickness produce less springback in the formed parts. Figure 2
shows the results of change in springback variations with respect
G2 G2 G2 to draw tension, for different materials with different curvature.
Substituting this in (30)
14
t 'T
'H = H 1 'T  (31) 12
H 2 1  10
Material 1 Curvature 1
G2 V y G2
Change in spring back in

8 Material 2 curvature 2
H1 6 L2 and H2 6 L2 6
 Material 1 Curvature 2
mm

G2 Et 2 G2 Et 2 4
2 Material 2 Curvature 1
Hence  'H 6 L2 'T (32) 0
Et 2V y 0 200 400 600
The Equation (32) gives the change in spring back for the Change in stretch tension in N
change in tension force created by the binder force control. The
change in spring back is the optimal one. Fig. 2. Variation in spring back with stretch tension

Volume 1 Issue 3 2009 171

 G.S. Hegde, J. Shivaprasad, R. Sridhar

3.1. Discussion
3.1. Discussion a X i i b (A1)
The simplest form for consideration of proof is,
It is clearly evident that springback varies linearly with the
yield strength. It projects that the materials of higher yield
a1 X 1  a 2 X 2  a3 X 3 b (A2)
strength have higher spring back. Hence it can be concluded that The Equation (A2) can be written as a1 X1  V1 0 (A3)
the ductile materials have less spring back effect than the brittle where V1 a2 X 2 a3 X 3  b
materials. It can be observed that the spring back is inversely
related to the thickness of the sheet used. By increasing the The solutions to (A3) are  X 1 ,V1  h,a1h
thickness it is possible to reduce the spring back. By stretching the Hence, a2 X 2  V2 a1h (A4)
sheet to higher tension using binder force control or a draw bead
the bending renders to be purely plastic and the spring back is where V2 a3 X 3  b
minimized. The spring back is also dependent on the length of the a1
The solutions to (A4) are,
autobody panel, through direct relation to the square of the half  X 2 ,V2  1  h, a2 h
a 2
length. It could not be neglected that the material properties like
modulus of elasticity and the plastic modulus contribute well to Hence a3 X 3  V3  a2 h (A5)
the spring back effects. For a given material the stretch tension
depends only on the thickness of the panel which is directly Solution to (A5) is,  X ,V  a2
related. It may be noted that the spring back in the longitudinal 3 3 1  h, a3h
a3
direction is less than in transverse direction. The stretch tension in
the longitudinal direction can be less compared to the transverse But V3
b
b  a3h, or h
direction in the panel. The linearized model predicts the change in a3
springback for a small change in thickness and the yield strength.
In the stretch bending it is assumed that the sheet slides over Hence X b
1
the tools as the punch is withdrawn. But with non-zero friction the an
sticking may occur at some point of forming process. Hence the a b for i 1 to n  1
assumption is invalid with the decreased value of binder force. X 11 1  i u
Proper control over the binder force is required to overcome the ai 1 an
sticking problem. From the solution to Xi it is evident that the maximization is
effective when ai<ai+1 i.e, when the coefficients of the terms in
(A1) are arranged in the ascending order of ai. This concept is
4. Conclusions
4. 
Conclusions made use in elasto-plastic analysis in case of forming the sheet
metals.
The purely plastic bending with stretching of auto body panel
with double curvature has been modeled and the expression for spring
back is presented. The elasto-plastic expression which is the Nomenclature
Nomenclature
combined result of Hookes and Holomanns law, has been solved by
interface theory, a new treatment tool that eases the process of ai Co-efficients in linear equation
solution. In the process the plastic stress, the plastic strain, the plastic b Output specification constraint
moment and tension in the sheet are computed. Under high tension E Modulus of elasticity
the sheet deforms by pure plastic bending. The spring back resulting G1,G2 Linearized co-efficients of tension
on the release of plastic moment is estimated. The plane stress H1, H2 Linearized co-efficients of springback
condition is assumed in the analysis. The optimization study to predict K Plastic Modulus
change in spring back under the constraint of change of tension has L Half length of the sheet
been presented. The interface theory is applied accompanied by the Mp Plastic Moment
linearization. The theoretical deliberation is supported by the n Plastic index
numerical implementation for the data accessed from the published Rp Punch radius
literature. The methodology is entirely new and different from the Rs Sheet radius
earlier publications on the relevant topic. With the control over stretch T Tension force
tension the behaviour of spring back can be minimized. The spring t Thickness of sheet
back shows dependency over material strength and thickness for Xi Interface variables
panel of given length. The biaxial stress strain, distribution in double H Change in springback
curved auto body panel generalizes the formulation. h Springback
e Elastic stress
p Plastic stress
Appendix
Appendix e
p
Elastic strain
Plastic strain
Hegdes interface modulus
Brief of interface theory [14]
Poissons ratio
The linear Equation with redundancy of unknown variables be,

172 Archives of Computational Materials Science and Surface Engineering

Interface driven optimisation of springback in stretch bending of autobody panels

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