ME 612
Metal Forming and Theory of Plasticity
17. Sheet Metal Bending
Assoc.Prof.Dr. Ahmet Zafer enalp
e-mail:
[email protected]Mechanical Engineering Department
Gebze Technical University
17.1. Elastic Plane Strain Bending
17. Sheet Metal Bending
Figure 17.1. Coordinate System for Analysis of Bending
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.1. Elastic Plane Strain Bending
17. Sheet Metal Bending
For elastic bending from plane strain asumption elastic strain in y direction is;
1
e
thickness
0 stress in z direction is;
y when
y x is
z
And
small
the
E
(17.1)
Using the above
z
is obtained.
(17.2)
Let r be the radius of curvature measured to the mid-plane and z the distance of an element from the
then elastic strain in x direction is;
mid-plane
y
(17.3)
(17.4)
true strain in x direction is;
ex
r z r
z
r
x ln 1
r
Dr. Ahmet Zafer enalp
ME 612
(17.5)
Mechanical Engineering
Department,
GTU
17.1. Elastic Plane Strain Bending
17. Sheet Metal Bending
For small strains:
ex x
But:
z
r
(17.6)
Placing Eq (17.2) into the above eq.;
1
e
y z
is x
obtained. In
this
case;
x
E
(17.7)
2 the plane strain elastic modulus.
and E is defined as
ex
(17.8)
E
z
2
1 r
E vz
y
1 2 r
(17.9)
E
1 2
Dr. Ahmet Zafer enalp
ME 612
(17.10)
Mechanical Engineering
Department,
GTU
17. Sheet Metal Bending
17.2. Springback in Sheet Bending
Here ideal elastic plastic material assumpttion is made. (Yield stregth; Y=constant). For plane strain y=
0. Yield criteria yeids
y ( X isobtained.
Z ) / 2
With the sheet metal assumption
If the above equality is placed in the von Mises
/ 2equation;
( equivalent
0) stress
is obtained.
3 Thus from yield condition;
(17.11)
2
Y
3
(17.12)
is obtained.
x =
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
Figure 17.2. Strain and stress distribution across sheet thickness. Bending strain (a) varies linearly across the section. For the non-work
hardening stress-strain relation (b), the bending moment causes the stress distribution in (c). Elastic unloading after removal of the
loads results in the residual stresses shown in (d).
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
In the Figure 17.2 (c) in order to form stress distribution we need to calculate bending moment;
M. Thus:
t/2
t/2
t / 2
M
x zdz material
2 wwith
(17.13)
For
ideal w
plastic
elastic deformation;
x zdz the assumption of neglectable central
Here
is defined to simplfy the formulation.
According to this;
2
Y 0
(17.15)
3
x=
(17.14)
term is obtained.
M 2 w x
t/2
t2
zdz w 0
4
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
Example 1:
A steel sheet, 0.036 inches thick, is bent to a radius of curvature of 5.0 inches. The flow stress; Y=33*10 3
psi (i.e. o=33*103 psi ).E= 33*106 psi.
1.
What fraction of the cross section remains elastic?
2.
What percent error does neglecting the elastic core cause in the calculation of the bending
moment?
Solution :
1. The elastic strain at yielding is ex=0 /E,
where E is the plane-strain modulus, E/(1-2).
The limit of the elastic core will be at z = r ex = r 0 / E .
E= 33*106 psi,
z= 5*33*103 /33*106= 0,005 inch. The elastic fraction is 2*0.005/0.036 =0.28 or 28 %.
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
2. To calculate the bending moment, for the elastic portion
(0 z 0.005) x = xE=zE/r and for the plastic portion( 0.005 z 0.018 ) ,
= 0 and bending moment;
E
M 2 w z 2 dz 2 w 0 zdz 10.42 w
Using the equation
which neglects the elastic core,
r
0
0.005
0.005
0.018
0.036 w 10.96w
2
Here,
M 33x10
The error is ( 10.694 10,.42 ) / 10.42 = 0.026 or 2.6 %.
3
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
The external moment applied by the tools and the internal moment resisting bending must be
equal, so Eq. (17.15) applies to both. When the external moment is released, the internal
moment must also vanish. As the material unbends (springs back) elastically, the internal
stress distribution results in a zero bending moment. Since the unloading is elastic,
M+M=0
(17.16)
Since the unloading is elastic,
x =E ex
(17.17)
The change in strain is given by
where r is the radius of curvature after springback. This causes a change in bending moment,
M of
z z
r r
(17.18)
t/2
t/2
M 2w x zdz 2w E
(17.19)
wE t 3 1 1
M
12 r r
(17.20)
Dr. Ahmet Zafer enalp
ME 612
1 1 2
z dz
r
r
Mechanical Engineering
Department,
GTU
10
17.2. Springback in Sheet Bending
Since
17. Sheet Metal Bending
if Eq (17.15) and Eq (17.20) are equated:
M after
M springback,
0
w 0t 2
wE ' t 3 1 1
12 r r
4
or:
(17.21)
The resulting residual stress,
1 1 3 0
(17.22)
r
r tE
This is plotted in Figure (17.2.d). Note that on the outside surface where z=t/2 the residual stress is compressive,
and on the inside surface z=-t/2 it is tensile x = + o/2.
3 0
1 1
0 E z
r r
tE
x x x 0 E ex 0 E z
(17.23)
3 z
x 0 1
t
(17.24)
Dr. Ahmet Zafer enalp
ME 612
0 z t
Mechanical Engineering
Department,
GTU
= -o/2 dir.
11
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
A similar development can be made for a work-hardening material. If
then, n
x Kdir. x n K z
where
n 1
Finally,
2
4
K K
Since M is still described
3 as before and
after spring back,
2 wK t
M
n
2 n r 2
2 n
(17.25)
Finally,
1 1
r r
6 K t
1
t
2 n E 2r
n
z
3 2 z
x K 1
r 2 n t
Dr. Ahmet Zafer enalp
ME 612
(17.26)
1 n
(17.27)
Mechanical Engineering
Department,
GTU
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17.2. Springback in Sheet Bending
17. Sheet Metal Bending
The variations of x, x, and x through the section are shown in
Figure 17.3. The magnitude of the spring back predicted can be
very large.
Figure 17.3. Stress distribution under bending moment and after unloading for a
work-hardening material.
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
13
17.2. Springback in Sheet Bending
17. Sheet Metal Bending
Example 2:
Find the tool radius necessary to produce a final bend radius of r=10 in. in a part made from a steel of thickness 0.03
inches. Assume a yield stress of 45.000 psi (0=45.000 psi) .
Solution :
, t=0.03,
psi,
Using above equation:
r=4.2 in.
6
Note: The springback problem0 is actually greater, since at a bend radius of 4.2 inches, the elastic core is
z=r0/E=4.2x45x103/33x106=0.0057 in. i.e., 38% of the cross section. This introduces 5 error in the moment value.
r 10
45.000
E 33 x10
1 1 3 0
r r tE
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
14
17.3. Bending with Superimposed Tension
17. Sheet Metal Bending
Such allowances for spring back would cause severe problems in tool design, but fortunately there is a relatively simple
solution. Often, as in stretch forming, the tooling does not apply a pure bending moment as assumed above. Rather,
tension is applied simultaneously with bending. With increasing tensile forces, F x , the neutral plane shifts towards
the inside of the bend and in most operations, this tension is sufficient to move the neutral plane completely out of
the sheet so that the entire cross section yields in tension. For such a case, the strain and stress distributions are
sketched in Figure Figure 17.4.
Figure 17.4. Bending with superimposed tension. With sufficient tension, the neutral axis moves out of the sheet so the strain is tensile
across the entire section, (a). With the stress-strain curve shown in (b), the stress distribution in (c) results. After removal of the
moment, elastic unloading leaves very minor residual stresses, as shown in (d).
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
15
17. Sheet Metal Bending
17.4. Sheet Bendability
If bend radius is too sharp, excessive tensile strain on outside surface can cause cracking,
while buckling can occur on the inside surface. The limiting values of r/t have been
shown to be function of the tensile ductility (% of elongation at fracture or % of area
reduction at fracture).
R
1
1
where
R
=
t 2 Ar inside radius of curvature (i.e. R/t=r/t-1/2),
And (
(17.28)
).
Ar
A0 Af
A0
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
16
17. Sheet Metal Bending
17.4. Sheet Bendability
The above correlation is not accurate for sharp bends (low r/t),
because the neutral axis shifts from the mid-plane and the amount
of shift depends upon the applied tension and the frictional
conditions. With tight bends (small r/h) the neutral axis shifts
toward the inside; there are several reasons for this.
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
17
17. Sheet Metal Bending
17.4. Sheet Bendability
Figure 17.5. Correlation of limiting bend severity, R/t, with tensile ductility
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
18
17. Sheet Metal Bending
17.4. Sheet Bendability
The cross section at the inside will increase while the outside decreases
and the magnitude of the true strain (and hence the flow stress in a
work-hardening material) increases faster with z in compression than
tension. As a consequence, the neutral axis moves inward to
compensate for the higher stresses and greater cross section. In nonsymmetric sections, transition from elastic to plastic flow will not occur
simultaneously on both sides of the bend and, consequently, as
yielding starts, there will be a shift of the neutral axis toward the
heavier sections.
Dr. Ahmet Zafer enalp
ME 612
Mechanical Engineering
Department,
GTU
19
