Springback Effect of Wipe Bending
Springback Effect of Wipe Bending
Abstract- Sheet metal stamped components find extensive use in engineering industry, in particular, in automobile like
passenger cars, two wheelers, domestic white goods like washing machines, air conditioning equipment and electrical control
equipment like switch gears and switches. The annual turnover in this sheet metal stamping industry itself extends to several
thousands of lakhs of rupees. This is assuming importance because the process supplies near net shapes without the need of
further machining. But in these sheet metal forming processes particularly in bending , defects such as rupture, wrinkling,
galling and Springback in formed parts might occur, whether during or after the process. The Springback phenomenon is the
most complex and challenging issue in industry.
This work presents a study of spring back in wipe bending metal forming process. Spring back is one of the most
sensitive features of the sheet metal forming, which occurs due to elastic recovery during unloading. The main purpose of this
work is spring back prediction of sheet metal copper alloy and investigation into the causes of the spring back, such as process
parameter, geometry of tools etc. In this work the prediction model of spring back in wipe bending process was developed
using finite element method code ANSYS APDL 14.0 and an over bend approach is applied to compensate the spring back
and the obtained spring back for different process parameters are validated by analytical method.
I. INTRODUCTION
A large variety of metallic parts of automobiles, aircrafts, building products and domestic appliances are produced by
deformation processing. This comprises manufacturing methods that are used to create the primary shape of products by plastically
deforming the material. Well-known examples are forging, rolling, extrusion, sheet metal forming and hydro forming. Sheet metal
forming is a special class of deformation processes in which blanks, with the thickness being much smaller than the other dimensions,
are formed into the desired shape. [9]Sheet metal forming is one of the most widely used manufacturing processes for the fabrication
of a wide range of products in many industries. The reason behind sheet metal forming gaining a lot of attention in modern technology
is due to the ease with which metal may be formed into useful shapes by plastic deformation processes in which the volume and mass
of the metal are conserved and metal is displaced from one location to another. [7]
Sheet metal forming operations consists of simple bending, ironing, wheeling, press brake forming, stretch forming, roll
forming, rubber-pad forming, stamping, flanging, spinning, embossing, bulging, hyper plastic forming, peen forming, explosive
forming, magnetic-pulse forming and deep drawing of complex parts [6]Indeed, the sheet metal products have become current also
due to low price, accuracy of dimensions, durability and favorable physical properties. In today’s industry, where the costs play a very
important role, the sheet metal products have replaced many products made by forming process. They have replaced also many
complex composed products. [7]In every industry, quality and productivity are major issues for being competitive. For example, a car
frame needs to be designed to achieve strength requirements and aesthetic aspects; on the other hand, cost of production and
repeatability is crucial to the business.
A stamping process has been one solution used in practice to achieve these goals in the sheet metal fabrication business.
However, Springback, a shape discrepancy between the fully loaded and unloaded configurations, undermines the stamping benefits,
since a major effort on the tooling design is needed to compensate Springback. In many industries, e.g. automotive industries,
Springback plays an important role in tooling and process designs. To effectively predict Springback for a potential application in
determining optimal tooling shapes and process parameters, understanding the mechanics of Springback, a mainly elastic recovery
process, is essential. [14]In the bending technology it is difficult to achieve accurate and repeatable angle of a bend. This problem is
caused by elastic Springback, which is considerable in processes of sheet metal forming [1-4]. Springback in processes of sheet metal
forming causes troubles in assembling processes, because Springback entails anomaly of required shape of the part. Economical
aspect of problems associated with Springback is in the USA solely in the sphere of automotive industry estimated on the 50 million
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dollar per year [5]. Springback is defined as a dimensional change of a shape after releasing a tool due to elastic effects [6]. In the
past, handy tables or graphs were the traditional ways used for prediction of Springback. For this purpose, today are frequently used
FE codes, which provide numerical simulations of sheet metal forming processes. [2]
A wiping die is as shown in fig. Here the work piece is clamped to a die block by a spring-loaded or fluid-cylinder pressure
pad, and the punch wipes the extended materials over one edge of the die. A bend radius is provided on the edge of the die block. A
radius or chamfer is often provided on the leading edge of the punch to prevent the wiping action from being too severe. [11]
PRINCIPLE OF SPRINGBACK
The elastic strains remaining in the bend region after bending load or pressure is removed will leads to a slight decrease in
the bend angle. This decrease in bend angle is known as spring back, as shown in below figure.
The Springback phenomenon will vary according to the material type, thickness and hardness. A larger bend radius will also
cause grater spring back. For forming process the material will be stressed beyond elastic limit so that the permanent deformation
takes place. The material status enters the plastic deformation region. Hence the sheet metal can be formed. Figure 2 shows the
principle of spring back. [14]
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The wipe-bending process plays a major role in sheet metal forming industry. In the bending process, after release of the load
by withdrawal of the punch, the metal tries to return to its original shape because of the elastic stresses. This phenomenon is so-called
‘‘Springback”. Springback is an important parameter in tooling design and obtaining the desired geometry of the part; hence
Springback prediction is a considerable issue in sheet metal forming.
Many factors could affect Springback in the process, such as material variation in mechanical properties, sheet thickness,
tooling geometry or forming speed. [3] In this work investigation of the factors, which are the reasons to cause the Springback are
studied and analyzed. And an optimum method to avoid the Springback will be presented.
PROBLEM STATEMENT
It is reported from the industry users that problems are encountered with such sheet metal stamped parts that
a) The parts are not as per the geometry they expected in spite of correct tools.
b) As the parts are bent to a required bend angle, after removal of load the desired bend angle is not achieved after removal of
load.
c) Such of the parts that are subjected to varying loads during use are undesirably losing elasticity and are permanently getting
into plastic deformation, leading to reduced component life.
It is now proposed in the work to investigate into the causes and possible suitable solutions to the problem. The following will be
investigated.
OBJECTIVES
1. It is known that the sheet metal stamped components undergo elasto-plastic deformation during the stamping process. The strain
in the component is large enough to cause yielding.
2. Because of the elastic portion of the strain, the component will ‘spring back’ by some amount.
3. One of the solutions for preventing geometric inaccuracy is to predict and correct the ‘spring back’ in the bending process.
4. The main objective is to study the causes for Springback and suggesting the method to compensate the Springback which we are
studying in this work.
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In the process, first the sheet is clamped between die and blank holder, and then the punch moves downward to bend the sheet. After
release of the load by withdrawal of the punch, the springback taken place and the change in the wall angle Ɵ, is defined to be a
measure of distortion.
ELEMENT TYPE
PLANE183
PLANE183 is a higher order 2-D, 8-node or 6-node element. PLANE183 has quadratic pure displacement behavior and is
well suited to modeling irregular meshes (such as those produced by various CAD/CAM systems).
The plane183 element is described by 8 nodes or 6 node which are having two degrees of freedom at each node i.e.
Translations in the nodal x and y directions. This element can be used as a plane element (plane stress, plane strain and generalized
plane strain) or as an axisymmetric element.
This element has plasticity, hyper elasticity, creep, stress stiffening, large deflection, and large strain capabilities. It also has
mixed formulation capability for simulating deformations of nearly incompressible elastoplastic materials, and fully incompressible
hyper elastic materials. [12]
Since in the wipe bending process there exists contact between the die surfaces and sheet metal and also the punch surfaces
to sheet metals surfaces hence it is necessary to provide the contact surfaces, if not the punch just passes through the sheet metal
without bending. Hence other than the Plane 183 element, in the FE modeling TARGE169 and CONTA172 are used, these elements
main function is to provide the contact between the respective surfaces in this process. [12]
TARGE169
TARGE169element is used as a ‘Target’ surface for different 2D models with the associated contact elements (CONTA171,
CONTA172, and CONTA175). The contact elements always try to overlay themselves on the solid elements showing the boundary of
a deformable object or body and are strongly in contact with the target surface, defined by TARGE169.
This target surface is separated or divided into set of segments which get paired with the respective contact surface through
some real constant. We can apply any translational or rotational displacement, temperature, voltage, and magnetic potential on the
target segment element. We can also apply forces and moments on target elements.
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In the first group simulations, the geometry parameters that are going to be changed are die shoulder radius (Rd) and the
remaining parameters are unchanged. And in the next groups of simulations, the geometry parameter that are going to be unchanged
are punch nose radius (Rp), Die gap clearance (g) and sheet metal thickness (T).
Die radius (mm) Punch radius (mm) Sheet thickness (mm) Die gap (mm)
0.2 0.2 0.3 0.3
0.5 0.4 0.4 0.4
0.8 0.6 0.5 0.5
1.1 0.8 0.6 0.6
1.4 1 0.7 0.7
1.5 & 2
In first group the effect of the die shoulder radius is analyzed i.e. five set of FE models are prepared with different die
shoulder radius and other parameters are unchanged as shown in below table.
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After conducting the FE analysis, we will get an optimum die shoulder radius at which the springback angle (value) will be
minimum that optimum radius is considered as constant (unchanged) during the analysis of other parameters.
Similarly in the second group five FE models with different punch nose radius were prepared and other parameters Rd, T and g are
unchanged.
Similarly the effect of sheet thickness (T) and die gap clearance (g) on the springback is analyzed with different sheet
thickness and die gap g. and the results of these are shown in the next section.
Material Properties
The material used in this analysis is copper alloy, is assumed to be isotropic elastic–plastic following the Von-Misses yield
criterion and isotropic hardening. The elastic properties are the modulus of elasticity, E =120GPa, Poisson’s ratio, m = 0.33 and
tensile yield stress, σyield = 260 MPa.The element used for the blank is 8 node plane183 linear plane–stress solid available in
software element library.
The contact surfaces are modeled with using linear contact elements. In FE simulations, the friction is neglected. The sheet
under the loading is analyzed by large displacement formulation. The number of increments for solution phase is dependent on the
sheet thickness.
The wipe bending or L-bending process was assumed under the plane stress deformation because the width of the sheet metal is
considered very less than the thickness. The material properties of Copper alloy obtained from the tension tests, as shown in Fig, were
used for the finite elementsimulations [7].
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350
Stress (Mpa)
300
250
200
150
100
50
0
0 0.02 0.04 0.06 0.08 0.1 0.12
Strain
Figure.7- Stress-strain relationship of copper alloy
Figure.8- FE Model
Meshing is an integral part of the analysis process. The mesh influences the accuracy, convergence and speed of the solution.
More importantly, the time it takes to create a mesh model is often a significant portion of the time it takes to get results from an
ANSYS solution.The process for generating a mesh of nodes and elements consists of three general steps:
Before we generate a mesh of nodes and elements, we must first define the appropriate element attributes. That is, we must
consider the following:
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Clearing meshes
Refining meshes
Once we have built our solid model, established element attributes, and set meshing controls, we are ready to generate the
finite element mesh. In this analysis Free mesh is used for Die and punch material. Mapped meshing is used for sheet metal
component.
Once the meshing of the finite element model is done. The next step is to apply the boundary conditions and constraints. In
this analysis of wipe bending process, there are three components (Die, Punch and sheet metal) to which the BC’s and constraints has
to be applied.
a. The Die was constrained in All DOF (UX, UY) on which the sheet metal was bent.
b. The sheet metal and the punch were constrained along UX.
c. The sheet metal part which is resting on the die surface is also fixed with application of pressure pad or pressure (in this case
pressure of 8-10 N/mm2 used).
d. Force in terms of displacement is applied with respect to time-load increments.
e. Contact and target were specified on the different surfaces of the Die, Punch and Sheet metal.
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After L- bending
One process parameter was examined at a time, while the other process parameters were remained the same. The effect of the die
corner radius on the springback has been discussed and shown in fig (9.5). The effect of punch radius on the springback is shown in
fig (9.6). It is observed in Fig(9.6) that the springback increases as the punch radius increases for the punch radii smaller than 1.2
mm, and then the springback decreases as the punch radius further increases. It implies that there is an optimum punch radius in the L-
bending process to reduce the springback.
However, the optimum punch radius is quite small and the effect of the punch radius on springback is not so obvious, hence, it is not
practical to reduce the springback by changing the punch radius. Figure (9.5) shows the effect of die gap on the springback. As seen in
Figure(9.5), the die gap has a significant effect on springback, and the larger the die gap, the more significant is the springback. Since
the sheet-metal is less constrained around the die corner when the die gap becomes large, resulting in larger positive springback .
In order to investigate the effect of die radius on the springback angle of the L bend or wipe bending process, the following strategy is
employed. Five groups of FE simulation models each with the different die radius varying from 0.2 to 1.4 mm and for each trails other
parameters are taken constant, i.e. sheet thickness is 0.3 mm, Punch radius is 0.2 mm and die gap of 0.3 mm.The FE simulation
response of springback angle for the die shoulder radius is reported in Table 1. And also using these results from simulation, the graph
of springback angle against die radius is plotted, as shown in table 6
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that the elastic strain for punch radius from 0.4mm to 0.8mm was increasing which led to greater springback and after sudden there
was decrease in springback values due to decrease in elastic strain with respect to tensile surface.
Table 8- Effect of punch radius on springback
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In the die gap trails the gap is provided equal to the thickness in order to avoid the reduction in the sheet metal thickness. And the
results for both are reported under following tables. And also in sheet metal thickness trails the gap is provided same as the thickness
of the metal.
a) Over bend
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The over bend method successfully prevents the springback of the sheet metal as shown in above fig. which is proved in the FE
simulations in this study. In order to investigate the effect of over bend to prevent springback, a previous analysis result i.e. for
die radius of 0.8 mm the springback angle measured was 2.4°. Now to prevent this springback angle FE models are prepared with
four different die undercuts that are 2.4°, 2°, 1.5° and 1° respectively. These trails are carried out to check the suitable amount of
over bend to obtain L-bend or 90° bend, this over bend method is based on trial and error.
2.4 -0.58
2 -0.5
1.5 -0.28
1 0.04 (optimum)
The above table shows the springback values for different die undercuts. As we see that the springback values are
negative (negative springback) up to 1.5° undercut. And at 1° over bend the springback value is 0.04° which is almost close to
90° or perfectly L-bend is obtained. Hence from this FE simulation we get that the sheet metal has to be over bent by an angle of
1° in order to prevent springback value of 2.4°. On the same procedure for a springback of 2.8°, the sheet is over bent 1.4° and
the springback values was 0.06° (89.94°). Hence in this it can be concluded that if the springback value of a metal is known then
it can be prevented by over bending the specimen with trial and error approach.
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V. CONCLUSION
From the investigation of Finite element analysis it shows that the die radius has a significant amount of effect on the
springback. The results from analysis for die shoulder shown that the increase in die shoulder radius increases the springback hence to
avoid the springback use of smaller die radius is recommended from this study. And also the punch nose radius has significant effect
on the springback, up to certain punch nose radius though it doesn’t have much effect as compared to the die radius on springback.
Apart from these two factors the die gap or clearance and sheet metal thickness also has a very appreciating amount of effect
on springback, from this analysis it shown that an sufficient amount of die gap has to be maintained (same as thickness of the sheet
metal) in order to compensate the springback and also to avoid some of the defects such as tearing. Closer or less clearance may lead
to damaging which results in waste of material and cost. Springback is also affected by the thickness; however this parameter depends
on the requirement for manufacturing.
An over bend approach is proposed to compensate the springback. After analyzing the different parameters responsible for
the cause of springback, the springback is controlled for some extent but cannot be eliminated. Hence the over bend approach based
on trial and error is chosen in this work by which the springback is almost eliminated. And for validation of this FE analysis a suitable
theoretical computation is done. This shows good agreement with the results from analysis.
VI. BIBLOGRAPHY
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[4] Fuh-Kuo Chen, Shen-Fu Ko ‘Deformation analysis of springback in L-bending of sheet metal’ journal of achievements in
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[6] Ivan sachy ‘Handbook of die design second edition’ Copyright © 2006, 1998 by IvanaSuchy., McGraw-Hill
[7] Filip Lindberg ‘Sheet Metal Forming Simulations with FEM’ Master’s Thesis in Engineering Physics, 30 ECTS jan 2011.
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[9] Jeong-Whan Yoona, Farhang Pourboghrat, Kwansoo Chung, Dong-Yol Yang Springback prediction for sheet metal forming
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