Materials and Design 32 (2011) 4430–4436

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Materials and Design

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Process parameter design of spring-back and spring-go in V-bending process using

Taguchi technique
Sutasn Thipprakmas ⇑, Wiriyakorn Phanitwong
Department of Tool and Materials Engineering, King Mongkut’s University of Technology Thonburi, Thailand

a r t i c l e i n f o a b s t r a c t

Article history: Bent parts of complex shapes with high precision are increasingly required. To achieve a high precision of
Received 15 December 2010 parts, especially the required bending angle, a suitable design of process parameters is strictly consid-
Accepted 28 March 2011 ered. In this study, process parameters of bending angle, material thickness and punch radius were inves-
Available online 31 March 2011
tigated. The finite element method (FEM), in association with the Taguchi and the analysis of variance
(ANOVA) techniques, was carried out to investigate the degree of importance of process parameters in
Keywords: V-bending process. The results revealed that the degree of importance of process parameters in V-bend-
Forming
ing process depended on the spring-back and spring-go. The material thickness has a major influence on
Elastic behaviour
Plastic behaviour
the spring-back. In contrast, in the case of spring-go, the bending angle has a major influence and closely
followed by the material thickness. In addition to predicting the degree of importance of process param-
eters by the combination of the FEM simulation, the Taguchi technique, and the ANOVA technique, by
facilitating an improvement in the quality of the required bending angle was strictly considered by opti-
mization of these process parameters corresponding with the spring-back and spring-go.
Ó 2011 Elsevier Ltd. All rights reserved.

1. Introduction analysis. Kim and Koc [6] investigated the spring-back

characteristics of aluminum sheet metal alloys in warm forming
Formation of high-precision sheet metal is one of the main conditions using the numerical method. Yu [7] investigated the
objectives in many manufacturing industries. It plays a signifi- variation of elastic modulus during plastic deformation and its
cant role in automotive industries, electronics industries, and influence on spring-back. Kazan et al. [8] predicted spring-back
housing-utensil industries. To fabricate the curved parts in the in wipe-bending process of sheet metal using neural network.
production of various items, with an economical set-up and Ozturk et al. [9] investigated the tensile and spring-back behav-
enormous range of parts of complex sizes and shapes could be iour of advanced steel of high strength (DP600) at warm temper-
fabricated; the sheet metal V-bending process is commonly ap- atures. Parsa et al. [10] studied the spring-back of double curved
plied. Accuracy in the dimension of bent parts, especially the aluminum/polypropylene/aluminum sandwich sheet by using
bending angle, is of utmost importance. In past researches, FEM simulation and experiments. Panthi et al. [11] studied the
numerous finite element method (FEM) simulation and experi- spring-back prediction of sheet metal bending process by using
mental works were conducted in understanding the bending fea- FEM. It is not only the occurrence of spring-back but also the
ture [1–22]. However, the spring-back was studied in most of occurrence of spring-go that has effect on the bending angle.
these researches. For examples, Zang et al. [1] studied the consti- In recent years, the spring-go has also been conducted to under-
tutive model for spring-back prediction in which the change of stand the bending feature as well as to achieve accuracy of the
Young’s modulus with plastic deformation is considered. Leu bending angle. Thipprakmas et al. [12–14] investigated the
and Hsieh [2] investigated the influence of the coining force on spring-go phenomenon, as well as the effects of punch height
spring-back reduction in V-die bending process. Wang et al. [3] and the ratio of punch to workpiece length. Bakhshi-Jooybari
studied the spring-back control of sheet metal air bending pro- et al. [15] studied the spring-back and spring-go of CK67 steel
cess. Tekaslan et al. [4] determined the spring-back of stainless sheet in V-die and U-die bending processes.
steel sheet metal in V-bending dies. Meinders et al. [5] studied With the bending process, there are various process parameters
spring-back prediction and optimization using the numerical with different adjustment levels, which may affect the spring-back
and spring-go as well as the bending angle. Although many
⇑ Corresponding author. Address: 126 Prachautit Rd., Bangmod, Thungkru, researches have been conducted, the process parameter design for
Bangkok 10140, Thailand. Tel.: +66 24709218; fax: +66 28729080. controlling the spring-back and spring-go has not been researched
E-mail addresses: [email protected], [email protected] (S. Thipprakmas). yet. In this study, therefore, the Taguchi and the analysis of variance

0261-3069/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2011.03.069
 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436 4431

(ANOVA) techniques were carried out to examine the degree of Table 1

importance of process parameters, including bending angle, mate- FEM simulation conditions.

rial thickness, and punch radius, in relation to the spring-back and Simulation model Plane strain model
spring-go. The commercial software DEFORM-2D was used as the fi- Object type Workpiece:Elasto-plastic, Punch/Die:rigid
nite-element simulation (FE-simulation) code to carry out the pre- Workpiece material A1100-O (rB = 92.5 MPa, k = 46%)
diction of spring-back and spring-go. The experiments were Flow curve equation r ¼ 160:4e0:22
performed to validate the FEM simulation results. The ANOVA tech- Angular punch radius (Rp) 2.5 and 3.5 mm
Angular die radius (Rd) 5 mm
nique is able to specify the process parameters that markedly influ-
Bending angle (h) 30°, 45°, 120°, and 135°
ence the spring-back and spring-go and yield information about the Workpiece thickness (t) 2.0, 3.0, and 4.0 mm
degree of importance of each process parameter on the spring-back Friction coefficient (l) 0.1
and spring-go. The results elucidated that the degree of importance
of each process parameter in bending angle was different in the case
2.2. Experimental procedure
of spring-back and spring-go. The material thickness has a major
influence on the spring-back. The bending angle has a major influ-
Referring to the author’s past researches [13,14], V-bending dies
ence on the spring-go closely followed by the material thickness.
and a 5-ton universal tensile testing machine (Lloyd Instruments
This difference in the process parameter having a major influence
Ltd) were used for the laboratory V-bending experiments with
on the spring-back and spring-go in the V-bending process could
the same FEM simulation conditions, the laboratory experiments
be clearly identified based on the stress distribution analysis. There-
were carried out to validate the FEM simulation results. Aluminum
fore, the achievement of the required bending angle depended on
(A1100-O) of 30 mm width and 3 mm thickness was used as a
the application of the optimal value of the process parameters and
workpiece material. The bending angle was examined using the
their favorable combination relating to the spring-back and
profile projector. The bending force was recorded and compared
spring-go.
with the bending force analyzed by FEM.

2. The FEM simulation, experimental procedures, and Taguchi 2.3. Taguchi method
method
In this study, two levels of the three process parameters, includ-
2.1. FEM simulation procedure ing bending angle, material thickness, and punch radius were ap-
plied. The experimental design of FEM simulation using the two
Fig. 1 shows the FEM simulation model. A half V-bending sim- level for three-parameter full factorial design (23) is shown in Table
ulation model with a die radius (Rd) of 5 mm was used to reduce 2. The spring-back and spring-go were the process responses. In
the calculated time. In this study, the model was a two-dimen- this study, to understand the effects of the process parameters,
sional plane strain 70 mm in length and 3 mm in thickness. The the Taguchi technique employing a generic signal-to-noise ratio
commercial analytical code for two-dimensional implicit quasi- for the ‘‘Smaller is better (SNS)’’ characteristics was considered
static finite element method (DEFORM-2D) was used as the FEM for the amounts of spring-back and spring-go as depicted in the
simulation tool. Automatic remeshing was set at every five steps following equation:
to prevent a divergence calculation due to excessive deformation. !
With reference to earlier research [12–14], Table 1 shows the de- 1X n
SNS ¼ 10 log y2 ð1Þ
tails of FEM simulation conditions and material properties. A n i¼1 i
punch radius (Rp) of 2.5 and 3.5 mm, a material thickness (t) of 2,
3, and 4 mm, and bending angles (h) of 30°, 45°, 120°, and 135° where n represents the number of experiments and y represents the
were investigated. The workpiece material was set as an elasto- process response.
plastic type with a rectangular element of approximately 3500 ele- In addition to the FEM simulation results of the spring-back and
ments. The punch and die were set as a rigid type. The material spring-go, the ANOVA technique was also applied to illustrate the
used was aluminum A1100-O (JIS) and its properties included ten- degree of importance of each process parameter that markedly
sile strength of 92.5 MPa and elongation of 46%. The constitutive influenced the spring-back and spring-go in the V-bending process.
equation was determined from the SS (Stress Strain) curve ob-
tained by the tensile testing experiment [12–14]. 3. Results and discussion

3.1. Application of ANOVA

Punch
The process parameters and their levels investigated in spring-
υb R 10 mm
back and spring-go are listed in Table 3. Table 4 shows the amounts
of spring-back and spring-go analyzed by FEM. The results show
θP
Workpiece t Table 2
Full factorial (23) experimental design for FEM simulation.
RP
Experiment Bending angle Material thickness Punch radius
R 10 mm No. (h) (t) (Rp)
1 Low Low Low
2 High Low Low
Die 3 Low High Low
4 High High Low
5 Low Low High
6 High Low High
Rd 7 Low High High
8 High High High
Fig. 1. FEM simulation model.
4432 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436

Table 3
Process parameters and their levels.

(a) Spring-back (b) Spring-go

Process parameters Levels Process parameters Levels
Low High Low High
Bending angle (h)/(°) 30 45 Bending angle (h)/(°) 120 135
Material thickness (t)/(mm) 2.0 3.0 Material thickness (t)/(mm) 2.0 3.0
Punch radius (Rp)/(mm) 2.5 3.5 Punch radius (Rp)/(mm) 2.5 3.5

1X 8
Table 4 S=N ¼ ðS=NÞk ð2Þ
The amounts of spring-back and spring-go analyzed by FEM simulation. 8 k¼1
Experiment Bending Material Punch The amount
no. angle thickness radius of SB and SG/ 8 
X 2
(h)/(°) (t)/(mm) (Rp)/(mm) (°) SS ¼ ðS=NÞij  S=N ð3Þ
i¼1
(a) Spring-back (SB)
1 30 2.0 2.5 0.58
2 45 2.0 2.5 0.45 3 
X 2
3 30 3.0 2.5 0.11 SSi ¼ ðS=NÞij  S=N ð4Þ
4 45 3.0 2.5 0.09 j¼1
5 30 2.0 3.5 0.70
6 45 2.0 3.5 0.60  
SSi
7 30 3.0 3.5 0.27 % Contributioni ¼  100 ð5Þ
8 45 3.0 3.5 0.20 SS
(b) Spring-go (SG) The S=N; SS, and percentage contributions calculated for each
1 120 2.0 2.5 0.40
process parameters in the case of spring-back and spring-go are
2 135 2.0 2.5 0.48
3 120 3.0 2.5 0.46 illustrated in Table 5. In the case of spring-back, the percentage
4 135 3.0 2.5 0.54 contributions of the material thickness, the punch radius, and the
5 120 2.0 3.5 0.33 bending angle were 83.6365, 13.9263, and 2.4372, respectively.
6 135 2.0 3.5 0.47 On the other hand, in the case of spring-go, the percentage contri-
7 120 3.0 3.5 0.44
8 135 3.0 3.5 0.52
butions of the material thickness, the punch radius, and the bend-
ing angle were 33.4050, 6.9883, and 59.6067, respectively. Based
on these statistical analysis results, it was found that the degree
of importance of process parameters in V-bending process de-
pended on the spring-back and spring-go. As shown in the results,
good agreement with the bending theory in which the spring-back
in the case of spring-back the process parameters of the material
and spring-go generated in small and large bending angles, respec-
thickness had the most influence, respectively followed by the
tively. Specifically, spring-back was generated in 30° and 45° bend-
small influence of the punch radius and the bending angle. In the
ing angles while the spring-go was generated in 120° and 135°
case of spring-go it was vice versa, with the process parameters
bending angles. To investigate the degree of importance of the pro-
of bending angle having the highest influence, closely followed
cess parameters, therefore, the ANOVA technique was carried out
by the material thickness.
in case by case of spring-back and spring-go. The ‘‘Smaller is better
(SNs)’’ characteristics, as shown in Eq. (1), were considered for the
3.2. Effects of process parameters on the spring-back and spring-go
spring-back and spring-go. The mean value of the overall S/N (S=N)
is expressed as Eq. (2), where, k is the number of experiments. The
Many past researches have been studied on the effects of pro-
sums of squares owing to the variations of the overall mean (SS)
cess parameters in V-bending process, including bending angle
and the mean of the process parameters (SSi) are expressed as
[4,11], material thickness [3,11,15], punch radius [12,15], and
Eqs. (3) and (4), respectively. The percentage contributions as
punch height [13,14]. However, most of these were studied on
shown in Eq. (5) were calculated which was generally applied for
the spring-back. Therefore, the effects of process parameters in
considering the degree of importance of each process parameter
V-bending process on the spring-go were rarely investigated. In
as reported in the literature [23,24].
this study, the effects of bending angle, material thickness, and

Table 5
ANOVA results.

Process parameters Bending angle (h)/(°) Material thickness (t)/(mm) Punch radius (Rp)/(mm)
30 45 2.0 3.0 2.5 3.5
(a) Spring-back
(S/N)ij 9.59 11.57 4.80 16.36 12.94 8.22
Sum of squares (SSi) 1.95 66.81 11.12
% Contributions 2.4372 83.6365 13.9263
(b) Spring-go
120 135 2.0 3.0 2.5 3.5
(S/N)ij 7.87 5.99 7.63 6.23 6.61 7.25
Sum of squares (SSi) 1.76 0.98 0.21
% Contributions 59.6067 33.4050 6.9883
 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436 4433

Spring-go value Spring-back value

0.80
t = 2 mm
0.60
t = 3 mm
0.40

0.20

/ (°)
0.00 Bending angle (θ ) / (°)
-0.20 30 45 120 135

-0.40

-0.60

-0.80

(a) Rp 2.5 mm
Spring-go value Spring-back value

0.80
t = 2 mm
0.60
t = 3 mm
0.40

0.20
/ (°)

0.00 Bending angle (θ ) / (°)

-0.20 30 45 120 135

-0.40

-0.60

-0.80

(b) Rp 3.5 mm

Fig. 2. Comparison of the amounts of spring-back and spring-go analyzed by FEM simulation with respect to the process parameters.

3.13 mm

4.75 mm
3.30 mm
10.52 mm
(a-1) θ = 30°, Rp = 3.5 mm, t = 2 mm (b-1) θ = 120°, Rp = 3.5 mm, t = 2 mm

4.72 mm

6.02 mm
4.36 mm
11.33 mm
(a-2) θ = 30°, Rp = 3.5 mm, t = 3 mm (b-2) θ = 120°, Rp = 3.5 mm, t = 3 mm

5.91 mm

6.90 mm
4.80 mm
12.87 mm
(a-3) θ = 30°, Rp = 3.5 mm, t = 4 mm (b-3) θ = 120°, Rp = 3.5 mm, t = 4 mm

(a) spring-back (b) spring-go

Mean stress (MPa) 3 mm

-150 -100 -50 0 50 100 150

Fig. 3. Comparison of mean stress with respect to the material thickness (Rd = 5 mm).
4434 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436

punch radius on spring-back and spring-go were clearly investi- material thickness [11,15], and decrease in punch radius [15].
gated and identified based on the stress distribution analysis. However, the spring-go was rarely reported. Only the author’s past
Fig. 2 shows the amounts of spring-back and spring-go analyzed research reported that the amount of spring-go decreased as the
by FEM with respect to bending angle, material thickness, and punch radius increased [12]. However, the mechanism of spring-
punch radius. The results showed the same tendency of spring- back/spring-go related to these process parameters and the degree
back and spring-go in both cases of punch radius of 2.5 and of important of each process parameter have not been clearly iden-
3.5 mm, as shown in Fig. 2a and b, respectively. Specifically, as tified yet. Base on the stress distribution analysis, the mechanism
the bending angle increased, the amount of spring-back decreased of spring-back and spring-go related to process parameters was
and the amount of spring-go increased. In addition, as the material clearly identified. Fig. 3 shows a comparison of mean stress with
thickness increased, the amount of spring-back decreased whereas respect to the material thickness. The results illustrated that as
the amount of spring-go increased. As the punch radius increased, the material thickness increased, the bending allowance zone
the amount of spring-back increased whereas the amount of and reversed bending zone increased. It was observed that the in-
spring-go decreased. The results obtained in this research are gen- crease in reserved bending zone was larger than the increase in
erally in agreement with those reported in the literature. These re- bending allowance zone. In addition, as the material thickness in-
sults were reported by FEM simulation and experiments that creased, the plastic zone across the thickness increased whereas
spring-back decreased with increase in bending angle [4,11] and the elastic zone over the neutral plane was approximately

3.13 mm
3.35 mm

10.52 mm 10.27 mm
(a) θ = 30°, Rp = 3.5 mm, t = 2 mm (b) θ = 45°, Rp = 3.5 mm, t = 2 mm

5.03 mm
5.00 mm

10.75 mm 11.08 mm
(c) θ = 45°, Rp = 2.5 mm, t = 3 mm (d) θ = 45°, Rp = 3.5 mm, t = 3 mm

Mean stress (MPa) 3 mm

-150 -100 -50 0 50 100 150

Fig. 4. Comparison of mean stress with respect to the process parameters in case of spring-back (Rd = 5 mm).

4.75 mm 4.95 mm
3.30 mm 2.90 mm

(a) θ = 120°, Rp = 3.5 mm, t = 2 mm (b) θ = 135°, Rp = 3.5 mm, t = 2 mm

5.27 mm 5.18 mm
2.87mm 3.00 mm
(c) θ = 135°, Rp = 2.5 mm, t = 3 mm (d) θ = 135°, Rp = 3.5 mm, t = 3 mm

Mean stress (MPa) 3 mm

-150 -100 -50 0 50 100 150

Fig. 5. Comparison of mean stress with respect to the process parameters in case of spring-go (Rd = 5 mm).
 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436 4435

Table 6
Required bending angle
Comparison of the amounts of spring-back and spring-go with reference to the 120.0
process parameters. FEM EXP

Bending angle (θ ) / (°)

119.5
Process parameters Case
(1) (Ref.) (2) (3) (4) 119.0

(a) Spring-back 118.5

Bending angle (h)/(°) 30 35 30 30
Material thickness (t)/(mm) 2.0 2.0 2.5 2.0 118.0
Punch radius (Rp)/(mm) 2.5 2.5 2.5 3.0
Spring-back value (°) 0.58 0.78 0.09 0.18 117.5
(b) Spring-go 117.0
Bending angle (h)/(°) 135 160 135 135
2.5 3.5 2.5 3.5
Material thickness (t)/(mm) 3.0 3.0 2.5 3.0
Punch radius (Rp) / (mm) Punch radius (Rp) / (mm)
Punch radius (Rp)/(mm) 2.5 2.5 2.5 2.0 2 3
Spring-go value (°) 0.54 0.38 0.43 0.52 Thickness (t) / (mm) Thickness (t) / (mm)

Fig. 6. Comparison of the bending angle between FEM and experimental results
(h = 120°).
constant. Therefore, with these characteristics, as the material
thickness increased, the amounts of spring-back and spring-go de-
creased and increased, respectively. Fig. 4 shows a comparison of 600
mean stress in case of spring-back, with respect to the bending an-

Bending force / (N)

500
gle, the reversed bending zone and the bending allowance zone in
FEM EXP
the case of a large bending angle slightly increased and decreased, 400
respectively, comparing with that of a small bending angle case.
300
With respect to the punch radius, the reversed bending zone
slightly decreased and the bending allowance slightly increased 200
as the punch radius increased that was clearly identified and were
100
generally in agreement with those reported in the author’s past re-
search [12]. The results illustrated that the material thickness had 0
a great major on the reversed bending and bending allowance 0 2 4 6 8 10 12 14 16 18
zones whereas the punch radius and bending angle had a small Bending stroke / (mm)
influence on the reversed bending and bending allowance zones.
Fig. 7. Comparison of the bending force between FEM simulation and experimental
Fig. 5 shows a comparison of mean stress in case of spring-go. results (h = 120°, Rp = 3.5 mm, Rd = 5 mm, t = 3 mm).
The mechanism of spring-go was clearly identified by the author’s
past research [12]. As the results, it was observed that the reversed
bending zone was larger than the bending allowance zone resulted researches that analyzed spring-back and spring-go with various
in the spring-go which corresponded with those reported in the bent shapes and different commercial FEM software showed good
author’s past researches [12–14]. The effects of process parameters agreement with the experimental results [1,3–5,13–15]. In this
could be explained in the same manner of the above-mentioned. study, the experiments were performed following the author’s past
The reversed bending and bending allowance zones slightly in- researches [13,14] in which the errors in analyzed bending force
creased and decreased, respectively, as the bending angle in- and bending angle were approximately 1% compared with the
creased. Whereas the reversed bending zone decreased and the experimental results. However, most of past researches were per-
bending allowance zone increased as the punch radius increased formed in the case of spring-back. In this study, experiments were
that was clearly identified and were generally in agreement with carried out to confirm the accuracy of FEM simulation results espe-
those reported in the author’s past research [12]. However, the in- cially for the case of spring-go. Fig. 6 shows the comparison of the
creases in reversed bending and bending allowance zones were bending angle between the FEM simulation and the experimental
largest in case of changing in the bending angle. results. Comparison of bending force between the FEM simulation
Similar to these results, based on the stress distribution the ef- and the experiments was also observed as shown in Fig. 7. Again,
fects of process parameters and the obtained results of the degree the FEM simulation results confirmed good agreement with the
of importance of process parameters analyzed by the ANOVA experimental results with errors of approximately 1% in bending
technique could be clearly identified. The material thickness and force and bending angle compared with the experimental results.
bending angle had a great major influence on the reversed bending
zone and bending allowance zone in the case of spring-back and 4. Conclusions
spring-go, respectively. To confirm the influence of these process
parameters, an increase or decrease of approximately 20% for each The FEM simulation, in association with the Taguchi and the
process parameter as listed in Table 6 was simulated and the ANOVA techniques, was used to examine the process parameters
amounts of spring-back and spring-go were also reported. The re- in V-bending process, including bending angle, material thickness,
sults confirmed that the effect of material thickness on the spring- and punch radius. Laboratory experiments were carried out to val-
back was greatest. Additionally, in the case of spring-go, the results idate the accuracy of the FEM simulation results. The ANOVA re-
also confirmed that the effect of bending angle on the spring-go sults illustrated the influence of each process parameter on the
was greatest, closely followed by the material thickness. spring-back and spring-go, together with their calculated percent-
age contributions. The material thickness, with its approximately
3.3. Comparing the FEM simulation and experimental results calculated percentage contribution of 83.6365%, had a major influ-
ence on spring-back. In contrast, the bending angle and subsequent
The accuracy of the FEM simulation results was validated by material thickness, with their approximately calculated percentage
laboratory experiments. It was also presented in many past contributions of 59.6067% and 33.4050%, had a major influence on
4436 S. Thipprakmas, W. Phanitwong / Materials and Design 32 (2011) 4430–4436

spring-go. These ANOVA results and the effects of process param- [6] Kim HS, Koc M. Numerical investigations on springback characteristics of
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