Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Presenting a new approach to reduce the spring-back angle of annealed copper sheets

Document Type : Original Article

Authors
Hadi Ebrahimi 1
Mohammad Morad Sheikhi 2
Mohammad Meghdad Fallah 3
1 PhD Student, Department of Mechanical Engineering, Shahid Rajaee University, Tehran, Iran
2 Associate Professor, Department of Mechanical Engineering, Shahid Rajaee University, Tehran, Iran
3 Assistant Professor, Department of Mechanical Engineering, Shahid Rajaee University, Tehran, Iran
10.22034/ijme.2024.429401.1886
Abstract
Various industries widely use forming processes to produce parts. The phenomenon of spring-back is an important issue related to forming process, which has a direct effect on the dimensional and geometric accuracy of the final part. In the present study, the preform force is used as a new approach to control and reduce the spring-back angle. To optimize the input parameters, the Taguchi test design method was used. In this design, preform force, annealing temperature, anisotropic and preform punch radius were considered as input variables and spring-back angle as quality index. The designed tests were carried out with the help of finite element model and experimental tests, and the spring-back angle was extracted for each test. By examining the results, it was found that the preform force and annealing temperature have the greatest effect on reducing the spring-back angle. The results of the experimental tests show that by choosing the optimal levels of the process parameters, the angle of the spring-back decreases significantly.
Keywords
Preform Force
Finite Element Model
Spring-back
Anisotropic
Taguchi
[1] Tekıner Z. An experimental study on the examination of springback of sheet metals with several thicknesses and properties in bending dies. Journal of materials processing technology. 2004 Jan 1;145(1):109-17. doi: 10.1016/j.jmatprotec.2003.07.005
[2] Esat V, Darendeliler H, Gokler MI. Finite element analysis of springback in bending of aluminium sheets. Materials & design. 2002 Apr 1;23(2):223-9. doi: 10.1016/S0261-3069(01)00062-0
[3] Marciniak Z, Duncan JL, Hu SJ. Mechanics of sheet metal forming. 2nd ed. Oxford; 2002.
[4] Lange K. Handbook of metal forming. Springer; 1985.
[5] Metals Handbook. 8nd ed. American society for metals; 1969.
[6] Karaağaç İ. The evaluation of process parameters on springback in V-bending using the flexforming process. Materials research. 2017 Jul 24;20:1291-9. doi: 10.1590/1980-5373-MR20160799
[7] Chikalthankar SB, Belurkar GD, Nandedkar VM. Factors affecting on springback in sheet metal bending: a review. International Journal of Engineering and Advanced Technology. 2014;3(4):247-51.
[8] Liu X, Zhao S, Qin Y, Wang C, Wan-Nawang WA. Size effects on the springback of CuZn37 brass foils in tension and micro W-bending. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2018 Dec;232(14):2439-48. doi: 10.1177/0954405417690557
[9] Wang J, Fu M, Ran J. Analysis of the Size Effect on Springback Behavior in Micro‐S caled U‐B ending Process of Sheet Metals. Advanced Engineering Materials. 2014 Apr;16(4):421-32. doi: 10.1002/adem.201300275
[10] Liu JG, Fu MW, Lu J, Chan WL. Influence of size effect on the springback of sheet metal foils in micro-bending. Computational Materials Science. 2011 Jul 1;50(9):2604-14. doi: 10.1016/j.proeng.2017.04.136
[11] Chen CC. Experimental study on punch radius and grain size effects in V-bending process. Materials and Manufacturing Processes. 2014 Apr 3;29(4):461-5. doi: 10.1080/10426914.2014.880468
[12] Shivaprasad C, Subrahmanyam A, Reddy NV. Effect of electric path in electric pulse aided V-bending of Ti-6Al4V: An experimental and numerical study. Journal of Manufacturing Processes. 2023 Aug 25;100:75-84. doi: 10.1016/j.jmapro.2023.05.018
[13] Liu X, Zhao S, Qin Y, Zhao J, Wan-Nawang WA. A parametric study on the bending accuracy in micro W-bending using Taguchi method. Measurement. 2017 Mar 1;100:233-42. doi: 10.1016/j.measurement.2016.12.007
[14] Kiswanto G, Mahmudah A, Priadi D. Preliminary Investigation of Micro-V-Bending. InMATEC web of conferences 2017 (Vol. 108, p. 06001). EDP Sciences. doi: 10.1051/matecconf/201710806001
[15] Liu X, Han X, Zhao S, Qin Y, Wan-Nawang WA, Yang T. Optimisation of micro W-bending process parameters using I-optimal design-based response surface methodology. Manufacturing review. 2021 Mar 2;8(7):1-10. doi: 10.1051/mfreview/2021005
[16] Wang C, Wang S, Wang S, Chen G, Zhang P. Investigation on springback behavior of Cu/Ni clad foils during flexible die micro V-bending process. Metals. 2019 Aug 15;9(8):892. doi: 10.3390/met9080892
[17] Podinehei R, Shahraki S, Ebrahimi H. The experimental and numerical study of the effect die parameters, grain size and ratio t/d on spring-back‎ in micro W-bending. Iranian Journal of Manufacturing Engineering. 2022 Nov 22;9(9):1-9.  doi: 10.22034/ijme.2023.338676.7 [In Persian]
[18] Fonseca F. Handbook of Die Design. 2nd ed. United States of America; 1990.
[19] Standard test Method for Plastic strain Ratio (R) for sheet Metal-E 517. ASTM International: 2019 Oct 31. doi: 10.1520/E0517-19
[20] Papeleux L, Ponthot JP. Finite element simulation of springback in sheet metal forming. Journal of Materials Processing Technology. 2002 Sep 9;125:785-91. doi: 10.1016/S0924-0136(02)00393-X
[21] Hai VG, Minh NT, Nguyen DT. A study on experiment and simulation to predict the spring-back of SS400 steel sheet in large radius of V-bending process. Materials Research Express. 2020 Jan 20;7(1):016562. doi: 10.1088/2053-1591/ab67f5
[22] Hill R. A theory of the yielding and plastic flow of anisotropic metals. Proceedings of the Royal Society of London. Series A. Mathematical and Physical Sciences. 1948 May 27;193(1033):281-97. doi: 10.1098/rspa.1948.0045
[23] Hong JH, Kim H, Han S, Kwon YN, Park H, Kim D. Bendability assessment of high strength aluminum alloy sheets via V-die air bending method. Journal of Materials Research and Technology. 2022 Sep 1;20:1481-94. doi: 10.1016/j.jmrt.2022.07.123
[24] Montgomery DC. Design and analysis of experiments. John wiley & sons; 2017.
[25] Chan WM, Chew HI, Lee HP, Cheok BT. Finite element analysis of spring-back of V-bending sheet metal forming processes. Journal of materials processing technology. 2004 May 1;148(1):15-24. doi: 10.1016/j.jmatprotec.2003.11.038
[26] Callister WD, Rethwisch DG. Fundamentals of materials science and engineering. 2nd ed. Wiley; 2007.
[27] Adelkhani A, Ebrahimi H, Attar M. The experimental and numerical study of the effects of welding angle on forming multilayered sheets in U-bending operations. Journal of Mechanical Science and Technology. 2020 Jan;34:239-44. doi: 10.1007/s12206-019-1225-x
[28] Hakan D, Mustafa Ö, Murat S. Effects of material properties and punch tip radius on spring-forward in 90 V bending processes. Journal of Iron and Steel Research International. 2013 Oct;20(10):64-9. doi: 10.1016/S1006-706X(13)60178-8