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ISSN: 2278-0181

Vol. 3 Issue 1, January - 2014

**A Review on Springback in Metal Forming
**

Dr. B. Linga Reddy1, Dr. B. Chennakesava Rao2, Dr. P. Raji Reddy3, Dr. P. V. R. Ravindra Reddy4,

1,3,4. Associate Professors, CBIT, Gandipet, Hyderabad-75;

2. Principal, CBIT, Gandipet, Hyderabad

Abstract

Springback occurs in metal forming after removal of the load due to elastic recovery. It is

difficult to develop analytical formulae for spring back and it should be compensated

iteratively by for which number of trials are required. Finite element analysis reduces the

number of trials reducing the cost, effort and time. In the present paper the review of

literature springback and on finite element analysis of spring back is presented.

Key Words: Metal Forming, Finite Element Analysis, Simulations, Springback

IJE

RT

It is the dimensional change of the formed part after the pressure of the forming tool has

been released. It results from the changes in strain produced by elastic recovery. During sheet

metal forming processes such as stamping and deep drawing where bending/unbending is

predominant, the region around the neutral plane in the material undergoes both elastic and

plastic deformation. When the punch has reached the final draw depth and is removed, the elastic

strain in the material is recovered, which produces springback in the part due to this nonuniform

stress distribution in the sheet. The discrepancy of shapes between a deep drawn product and the

designed one due to springback must be compensated for, at the tool design stage in order to

guarantee its function and assembly with other parts. It is, however, so difficult to predict and

estimate the amount of compensation for springback that tool modification relies on the

experience or a trial-and-error procedure in the press shop. This compensation procedure

requires extra try-out time, which increases the cost for the tooling and product development

time. Partnership for a New Generation of Vehicles (PNGV), a wing of the United States

Council for Automotive Research (USCAR), identified sixteen manufacturing technologies that

need to be addressed in order to improve automotive manufacturing [1] The ‗‗springback

challenge,‘‘ is one of these crucial manufacturing areas. In a forming process such as deep

drawing, it remains to this day one of the great challenges and one of the greatest problems for

the manufacturer. The preferred use of high-strength materials such as dual phase steels in many

modern manufacturing processes aggravates the problem of increased springback.

Springback is however affected by the complex combination of bending, unbending, and

stretching imposed on parts during deep drawing process. Therefore, the proper understanding of

the effects of process parameters as well as material properties on springback is so useful to

effectively design the processes.

The magnitude of springback depends on the bending moment, which intern depends on

the through thickness stress distribution at each point in the plane of the sheet at the end of the

drawing operation. The accuracy of springback prediction depends on the development of the

internal stress distribution through out the drawing operation, which makes it sensitive to a range

of variables.

IJERTV3IS10285

www.ijert.org

646

Fig 2. and possibly stretching the sample over the cylinder. and a fixed or rolling cylinder to simulate a tooling radius over which the strip sample of 50mm wide is drawn.ijert.International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol. sheet loading depends on the complex interaction between the material behavior. resulting in a load reversal in the material. bending. In this test a channel is drawn from a rectangular blank. The lower actuator is set to displace at a constant speed. unbending.2014 IJE RT Parametric studies were carried out experimentally [2-5]. sheet loading may be controlled directly and accurately. 2. Springback error is studied after removal of the load. but has the advantage of simplicity. More importantly. as well as blank holder forces and displacements Fig. 3 Issue 1. As such. January . The upper actuator is programmed to provide a constant restraining force. thus drawing. since in real press forming operations.1 Schematic draw bend test and unloaded specimen shape after bending Another test used to find out springback is U bend channel test as shown in Fig. Schematic diagram of U bend channel test IJERTV3IS10285 www. At the end of the test. One of the experimental tests is draw/bend test [23] as shown in Fig. contact and friction. It consists of two hydraulic actuators oriented at a 900 angle. v. the sheet metal strip undergoes bending and unbending under constant tension. In this case. draw-bead configurations. it is exemplary for a number of sheet forming operations. Number of authors [25-26] have simulated the draw-bending test as a well characterized forming operation that produces springback similarly to industrial stamping forming operations. Fb. 1. the sample is allowed to springback by the removal of the specimen from the grips and the springback angle Δθ is measured.org 647 . numerically [6-8] and Analytically [9-22].

The classical analytical approach assumes simple tool description and material properties. relatively simple forming processes such as draw-bending or deep drawing of a cylindrical cup are utilized. Monfort and Bragard [20] extended this procedure by using a cantilevered model with a nonuniform moment distribution from the contact point to the outer sheet.al. has greatly facilitated the numerical simulation of springback.2014 IJE RT Although the above two tests are preferred in understanding certain aspects of springback. In combination with experimental work.33]. Numerical methods are needed for more complicated cases. the finite element method has been widely utilized to predict and understand the springback. such approaches and programs have been utilized for predicting springback after simple forming operations.ijert.28] . [27.[29]. and the solution procedure [54-56]. Cao et al. Wang [38] conducted the analytical study by assuming that the bending moment vanishes as the elastic recovery occurs. These are then split open perpendicular to the circumference of the ring. This results in the release of energy stored in the material during deep-drawing and residual stress development. There was also considerable research in the area of the establishment of the possible influence of algorithmic and numerical aspects of the simulation on the corresponding results. 3 Issue 1. a cylindrical cup is deep drawn and then cut into several closed rings. they are not close enough to deep drawing operations usually found in automotive stamping operations. cylindrical tool bending [39]. However cutting and splitting of the rings with out induction of residual stresses especially in case of thin walled cups is a difficult task. the increased availability of commercial programs for the simulation of forming processes like LS-DYNA. The extent of ring opening indicates the amount of the springback. Deformation analysis of this test has been presented by Cedric et. flanging [40]. the integration scheme [48-50].g. With the rapid development of computational power and solution techniques. Jeunechamps et al. the 2D draw bending benchmark problem by Mattiasson et al. developed a closed form method to predict springback in creep age-forming and investigated the effects of geometric parameters on springback of aluminum plates. Numerical examples have shown that the computation of IJERTV3IS10285 www.org 648 . which involves the die corner and sidewall curl regions. plane strain pure bending [31] plane strain bending [32. [30]. Hence. Examples of the FEM springback analysis of 2D formed parts include the cantilever beam analysis by Kawaguchi et al. The deep drawing part is highly developed and yields reliable results. process conditions [52-53]. These include the material model [45-47]. the element type [51]. In addition. which limits the analytical approach to simple geometries and simple deformation. A typical springback simulation consists mainly of two parts: The deep drawing process followed by the computation of the elastic springback. It only provides a useful basis for the qualitative understanding of process and property effects on springback. and biaxial elastic-plastic pure bending of a rectangular plate [35] and beam [36]. Stampack.V-die bending [41-43] and U-channel forming [44]. AutoForm. Examples of this approach include the springback analysis of pure bending with elasto-perfect plasticity [30]. plane stress bending [34] with additional tensile force.. [21] proposed a linear moment distribution in the contact area and that model compares favorably with the experimental results of Liu [22]. The major difficulty with the analytical solution is due to the lack of understanding of the stress distribution throughout the sheet. e. The analysis of process effects was mainly performed for 2D draw forming.International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol. [31] and He and Wagoner [23]. In this process. To this end. leading to springback. January . DYNAform. PAM-STAMP. To simulate the deep drawing process more closely split-ring test was proposed by Demeri et al.

which causes the affected area to curl due to release of residual bending movement. [44] investigated the springback of draw bend tests including parametric studies on numerical and physical parameters such as the size of meshes. The advantages of the FEM method over analytical methods are its capabilities to model complicated tool descriptions and realistic constitutive behavior. Geng and Wagoner [39] analyzed springback angles and the role of anticlastic curvature especially with large restraining back forces using a series of simulated draw bending tests in conjunction with an anisotropic hardening rule and four different yield functions. 1. 3 Issue 1. In some of the approaches. low order shell-elements yielding an algebraic rate of convergence are applied. For the elastic springback the constitutive relation that considers the elastic and plastic parts together has to be used. Fig. where as Kim and Thomson [54] described in terms of ‗θ‘and ‗ρ‘ IJERTV3IS10285 www.2014 IJE RT elastic springback based on explicit finite element codes may yield unreliable results. Chung et al. Angle springback is the change in the final bend angle after the blank undergoes bending by release of elastic component of bending movement. Li et al. One major trend in metal forming simulation is to ignore the elastic deformation of the structure compared to the plastic part. the number of integration points.International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol. More complicated loading paths arise during processes such as deep drawing of closed structures. Many simplified approaches have been proposed in simulation and design of the metal forming process.11 Variables used to measure the springback in ‘U’ bend test For this test Lee and Yang [42] described springback error in terms of angles ‗θ‘ and ‗β‘ and side wall curvature ‗ρ‘. and restraining forces. [51] and Lee et al. while the geometrically non-linear elastic springback is computed with the p-version of the finite element method. In case of channel forming it can be defined with the angle springback of the corner bends and side wall curl (Fig 3). the analysis with implicit codes is more reliable but in terms of computer resources more demanding.ijert. [52-53] evaluated the springback of a modified automotive part by implementing the modified combined isotropic-kinematic hardening and nonquadratic anisotropic yield function. Where a side wall curl is a result of blank bent and then unbent under tension while passing over a die radius. In particular. tool radius. Various measures are developed for the quantification of springback. On the other hand. The p-version of the finite element method is also tried for computing efficient and reliable approximations of the elastic springback [57].org 649 . bending and unbending represent a loading path change of the load-reversal type in which isotropic and kinematic hardening are the principle hardening mechanisms. the deep drawing part is computed with a commercial h-version code. January . Usually.

the lower the elastic modulus. However. For a given material and strain the springback increases with the ratio between the lateral dimensions of the sheet and its thickness. The error in the flange length is decreased when the blank holder force or the clearance is increased. These normals are used to determine the global shape error by considering the bent angle and twist angle between the two shapes‘ average normal vectors. process and tooling parameters such as material properties. the higher the yield stress. The global shape error is calculated using the average surface normals on arbitrarily defined patches of the component for both the desired and actual shapes. Kase et. Karafillis and Boyce [56] used root mean square (RMS) of the vertical distances between the desired shape and actual shape as the shape error measure. The floor angle springback is decreased by increasing the blank holder force.e. the punch nose radius has an influence on springback within a relatively narrow range. So the U bend channel test or draw bend IJERTV3IS10285 www.org 650 . Webb and Hardt [55] developed shape error measure using Discrete Fourier Transforms (DFT) for their iterative die design. However. Fourier models. In total they concluded that springback error decreases with the increase of blank holder force or increase of die corner radius and there is no consistency in the results given by clearance. because it is difficult to determine where the wall curvature begins.al [59] have studied the effect of blank holder force die corner radius and clearance from the U bend tests. and the punch nose radius decreases. friction condition. however.al [57-58] used differential geometry to determine the principle curvature differences between the desired and actual shapes to calculate the local shape error of the component. binder force. Moreover using angles and the radius of curvature is only useful for U bend test. The coefficients of DFT decription of shape is able to reduce the dimensionality of die design down to a small set of values that is much easier to manipulate. Kim and Thomson [54] have also suggested that the clearance has very small influence on the angle springback and side wall curl. sheet thickness. Research has been carried out to find out the effect of various material.al [59] used point distribution model (PDM) to measure springback by comparing an artificially created non springback shape to the formed shape that has inherent springback. Rolfee et. the gap to thickness ratio decreases.2014 IJE RT only. They found die radius and tool gap directly effect the final geometry of the channel.Rolfe et.ijert. B.International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol.F. The RMS error does not give any indication of shape error. The advantage with this method is that the surfaces to be compared do not need to be aligned. 3 Issue 1. From the above it is observed that the effect of parameters on the springback varies from test to test. it can be used for comparison. The floor angle springback is increased by increasing the combination of die radii and clearance. But these are hard to measure precisely. The relationships that exist between springback and these parameters are extremely nonlinear with multiple interactions. As the case of Fourier models the surfaces of the shapes need smoothing if there are discontinuities before the shape error description is utilized. and the error in the flange length is increased when the die radii is increased. The extended flange length shows decrease in error as the blank holder force or die radii is increased. and tooling geometry. etc on the springback. and the greater the plastic strain. B. The changes in the principle curvature calculated on the sample on the surface of the component are divided into mount. the binder force increases. It is observed that the springback is greater. But in the flanging process it found that springback decreases as the die corner radius decreases. January . suffer the problem that discontinuities such as corners or edges are difficult to describe unless some smoothing is done to the surface that is being modeled. These two parameters are not independent in particular with the springback and side wall curl effects. i. it has less influence at a larger nose radius [60].F. valley and twist. The flange angle springback appears to decrease by increasing the blank holder force and die radii.

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