Ain Shams

University Faculty
of Engineering
Design &
Production Dep.

Theory of Metal Forming MDP 381s

Fall 2023

Lab report (1)

Subject:

Spring back in Metals

Student Name: Andrew Ashraf Zakaria

Student ID: 2000021

Remarks: Degree:
Introduction
The spring back effect is also
known as elastic recovery or
elastic spring back. It is a
phenomenon observed in metals
and other materials when they
are subjected to deformation and
then released. When a metal is
bent, stretched, or compressed,
this make a change in its shape
due to the applied external
forces.

During deformation, the metal's atoms and

crystal structure are temporarily displaced from
their equilibrium positions. This displacement
causes the metal to store elastic potential
energy. When the external forces are removed,
the metal attempts to return to its original
shape and size, releasing the stored energy. This
tendency(need) of the metal to restore its
original state is known as the spring back effect.

The spring back effect can be significant in materials with high elasticity, such as certain
types of metals. It is commonly observed in processes like bending, forming, or stamping
of sheet metal components. The degree of spring back depends on various factors which
will be discussed.
Spring back factor (K)
The spring back factor, also known as the spring back coefficient or spring back ratio, is a
numerical value that quantifies the degree of spring back experienced by a material after
deformation. It is used to describe the relationship between the initial deformation and
the amount of elastic recovery exhibited by the material.

We will discuss the spring back effect in bending case.

K: spring back factor

Ri: initial radius of bent(radius of die)
Rf: final raduis of bent after spring back effect
t: thickness of workpiece
Tools needed

1) Vernier caliper

2) Vernier protractor
Machine used
Fly press
Calculations

Initial lab data:

Used formulae:

k_actual = alpha_f / alpha_i

k_theoritical = (R_i + (t/2)) / (R_f + (t/2))

R_i / R_f = 4*((R_i * y)/(E * t))^3 - 3*((R_i * y)/(E * t)) + 1

R_i = 4

alpha_i = 90

R_f = (R_i) / (4*((R_i * y)/(E * t))^3 - 3*((R_i * y)/(E * t)) + 1)

Graphs:

Comment: the readings of this specimen are not enough to study as we only studied the 0.5 thick-copper
plate so we got only one theoretical point.

It’s not acceptable(logically) that 2 specimens of same material with same thicknesses to have different
spring back factor(indicated by the vertical line) so the only acceptable explanation is that the value of
the upper point has a small error(accepted) and the lower point has a large error(this is already reported
from the observer of the experiment).
Comment: Here, the theoretical graph is opposite to the actual graph, this could occur as a result of
human error during the experiment as the expected behavior is direct relation between the spring back
effect and the thickness of the bended plate
Comment: Here the values of theoretical and actual spring back factor are near from each other but only
if we excluded the second experimental value(may be there was an error during taking this value).
Comment: Here the 2 graphs are nearly the same except for the last experimental value which has a
small error.
Comment: Here both of the graphs show that the relation is direct but the experimental values have a
relatively high error especially at the third reading.
Overcome spring back effect:
1. Overbending: One method is to intentionally overbend the material during
the initial deformation. By bending the material slightly beyond the desired
final shape, it is possible to achieve the desired shape after the release of
external forces.

2. Compensation Techniques: Compensation techniques involve adjusting the

tooling or process parameters to account for the spring back effect. This can
include modifying the die geometry, applying additional force or pressure
during forming, or adjusting the tooling design to incorporate preloading or
back-tapering. These techniques help counteract the spring back and achieve
the desired final shape.

3. Heat Treatment: In certain cases, applying heat treatment to the material can
help reduce the spring back effect. Processes like annealing, stress relieving,
or tempering can alter the material's internal stresses and improve its
formability while reducing the tendency to spring back. Heat treatment
techniques should be optimized based on the specific material and forming
process.

4. Process Optimization: Optimizing the forming process parameters, such as

tooling design, feed rate, temperature, lubrication, and forming speed, can
have a significant impact on minimizing spring back. Experimentation and
process simulation techniques can be employed to optimize the process
conditions and achieve the desired shape with reduced spring back.

It's important to note that the specific approach to overcome spring back may vary
depending on the material, forming process, and desired final shape. A
combination of these techniques is often necessary to effectively control and
reduce the spring back effect in metal forming operations.
Resources:

https://blog.spatial.com/springback-compensation

https://www.machinemfg.com/solve-stamping-bending-springback-
problems/

https://www.shenchong.com/bending-springback-causes-measures.html
Google screenshots: