Experimental and numerical prediction of spring back of homogenous sheet metals

Abstract

Forming is the most important manufacturing process. Forming is the process of converting the geometry to the required shape. Forging, extrusion, rolling and bending are some of the important forming process. The forming process includes larger deformation of the structure either with temperature or without temperature application. But in the every mechanical process certain defects exists due to the inherent resistance property of the material for forming it to the required shape. Bending of sheet metal is the most prevalent and needed process in the production industry. This forming process of sheet metal has wide application in the areas of aerospace, architectural, medical, telecommunication, defence and electronics. One type of defect is spring back and is very important phenomenon which makes the object non-suitable in case of rigid requirements. Spring back phenomenon with steel material is analysed using Finite element software Ansys. The three input parameters are considered for finding the spring back effect. Initially the sheet metal thickness effect on spring back is analysed. Eulerian contact definitions are created between the punch, die and sheet metal with large deformation effects. The displacement loading is applied through the punch. The results for vonmises stress, residual stress, plastic strain, spring back deformations are captured and tabulated. Similarly the analysis is continued with depth of forming process and its effect on spring back. The results shows with the thickness spring back values are coming down but with the depth of deformation spring back values are increasing newline