Document Type : Research Paper

Authors

Department of Mechanical Engineering, Higher Institute of Technological Studies of Sfax, ISET de Sfax, Tunisia

Abstract

Bending is one of the most frequently used processes in the sheet metal products industry. The major users are mainly the automotive, aeronautics and electrical engineering industries. It is necessarily a cold forming operation of a flat material, with or without lubricant, obtained notably by exceeding its elastic limit. After retraction of the tools and relaxation of the stresses, a springback consequently occurs and a permanent deformation persists causing certain geometric modifications of the product. As a matter of fact, this phenomenon, will absolutely affect the angle and curvature of the bend, for such reason it must be taken into consideration in order to manufacture sheet metal parts bent within acceptable tolerance limits. However, the value of this springback is influenced by a multiplicity of process parameters, such as the thickness of the sheet, the hold time of the bending operation, the material properties and last but not least the depth of strike of the tool. In this paper, we have developed a model for predicting springback in the air V-bending process using the design of experiments method. Four three-level factors were considered in order to model springback in using the response surface method (RSM). The experimental tests were carefully carried out on a HACO press brake and on aluminum, ordinary steel and stainless steel specimens with different thicknesses. The in-depth study of the response surfaces to the different tests with the method of analysis of variance (ANOVA), allowed us to determine a robust empirical model linking the springback to the variables of the study. In addition, several relevant numerical simulations using the finite element method (FEM) with software (Abaqus) were performed to predict the evolution of springback when varying the parameters in the field of design of experiments. In fact, the comparison of the values predicted by the two approaches shows a satisfactory agreement.

Keywords

Main Subjects

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