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Materials

& Design
Materials and Design 27 (2006) 251258
www.elsevier.com/locate/matdes

Short communication

Determining springback amount of steel sheet metal


has 0.5 mm thickness in bending dies
a,*
Ozgur Tekaslan eker b, Ahmet Ozdemir
, Ulvi S b

a
Army Academy, Ankara, Turkey
b
Faculty of Technical Education, Gazi University, Ankara, Turkey

Received 6 April 2004; accepted 11 October 2004


Available online 2 December 2004

Abstract

Importance of bending dies is very wide in sheet metal industry. Knowing that springback amount of bending material in bending
dies is as important as the die itself, because the material leaving the die should be within the allowed tolerance limits. Therefore, in
this study the subject of bending dies and springback in bending process has been researched. In order to nd springback in bending,
a V shaped die is designed and it has been aimed to nd out how much can steel sheet metal materials resile in various angles and
to bring forward springback graphics to add literature. There is little satisfying information in the literature regarding this issue. In
order to reach a conclusion, 15 dierent dies have been prepared, more than 150 samples, each of which has been bent at least 10
times, have been bent and the obtained angles have been measured with prole meter. The acquired results have been statistically
evaluated in a computer media and converted to graphics.
 2004 Elsevier Ltd. All rights reserved.

Keywords: Bending dies; Springback; V-bending

1. Introduction have brought forward all functions to act on spring-


back and have determined how to minimize such
Many researches conducted in the last 15 years have functions.
indicated that springback has a very important role in Springback can be minimized by means of die design,
sheet metal industry and studied how this permanent however it cannot be eliminated at all. To decrease
physical variation can be avoided. It has been observed springback, compression to minimum is one of the most
that, the one common point of all these researches is important problems in die design. If springback cannot
based on estimating or determining the amount of be estimated exactly beforehand, in order to nd out the
springback beforehand and accordingly designing and value to substitute springback as well as proper shaping
later manufacturing of dies to be based on the consid- parameters tests one after the other are performed to
eration of this springback amount. Whereas, some nd out springback amount. This will lead to wastage
researchers, in order to minimize springback amount, of time and material and the most important of all in-
have dealt with bipartite functions of both die and crease in cost. Therefore, knowing beforehand that
material thus have brought forth ideal die or matrix springback amount has cardinal importance, some of
measurements. On the other hand, some researchers these researches are presented below.
One of the most important studies that has been per-
* formed on bending was Hills basic sheet metal bending
Corresponding author. Tel.: +90 312 417 51 90/4323; fax: +90 312
418 32 26.
theory. Hill brought forward complete solution theory
E-mail address: tekaslan@yahoo.com (Ozgur Tekaslan). of the movement of perfect and natural axis of soft

0261-3069/$ - see front matter  2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.10.006
252 Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258

metals along bending. In addition to this theory Pros- joint study with Forcellese and his fellows by employ-
kass perfect bending of stress deformation hardening ing nite elements method. As a result, they have
theory has been improved by Crafoord. Crafoord, while found out that nite elements method can be employed
improving this theory, found out results of taking back in the calculation of springback as well as calculation
loading of Baushinger eect and adopting actual stress of die parts and supported these data with experiments
model for the existing place of at surface and un- [1113].
stressed surface between bers. With Crafoords theory, Yuan [14] tried to lessen springback in material sub-
it is possible to calculate stress distributions. On the jected to plastic deformation through redistribution of
other hand, Verguts and Sowerby studied individual exible stresses inside the material after being released
deformation of bers without considering Baushinger from the eecting load. Up to now, springback was lim-
eect [1]. ited to homogenous material. Yuan, after increase in the
In bending processes, in order to achieve the desired usage of composite materials in engineering, has re-
perfect bending prole, stressstrain distributions are searched and presented a mathematical model solution
very important. Bending, generally, involves placing a to determine springback acting on such materials. Lo
sheet of metal over the matrix on the press bed and forc- et al. [15] have researched conformity of springback of
ing compression of the punch, which is mounted on the metal parts and surface tension deformations to power
press ram, inside the larger die, called the matrix or, sim- transfer sciences in their researches.
ply, die and as a result bending of sheet metal around Wang et al. [16] have developed a computer program
the punch tip. At this moment, sheet metal exceeds pos- named BUKME for bending in air and bending in die
sible springback amount and springback value. During processes and U die, V die simulation. Results of simu-
bending process, while one side of the sheet metal is sub- lation were compared by experimental results.
jected to intensive forcing of compress stress on one sur- On the other hand, Wang, Kinzel, Altan; accompa-
face, the other surface is subjected to tensile stress. nied by Tsujio and others; Ling, Murty and Everhie;
While sheet metal material is bent inside the die, on Zhang and others; Schmoeckel and Beth; El-Domiaty
the section standing in the neutral axis, namely, the side and colleagues have conducted studies on mathematical
subjected to forcing compress stress, the sheet metal models to avoid springback [1923].
material is wider than its original width, whereas sides
staying out of the natural axis and trying to be pulled
by the material are smaller than their original width
2. Springback
[15].
Kwok and Lee have conducted a research studying
Since all materials have limited elastic modulus, when
clever machines employed in unmanned exible sheet
a load acting on plastic deformation is relieved from the
metal manufacturing systems and calculating mechanic
material, it is followed by several elastic improving. In
specication dierences in materials arising from their
bending process, elastic limits of materials are exceeded,
production during bending process [6]. Bauer and Kho-
but ow limit thereof cannot be exceeded. Therefore, the
dayari [7] have performed experiments through CNC
material still keeps a portion of its original exibility
tensile machines by changing bending angles and bring-
character: When the load is released, the material on
ing forward a mathematic model in order to nd out
forcing compress side tries to enlarge, whereas the mate-
material die parameters. This machine has the ability
rial on tensile side tries to shrink. As a result, the mate-
to monitor bending angle.
rial tries to springback and the bended material by
The rst objective of the research conducted by Shu
exing slightly tries to open. We name this nature of
and Hung [8] was to employ nite elements method to
material as springback. This is indicated in Fig. 1. And
analyse the relation between springback and variables.
if noticed, it can be seen that the last bending angle fol-
Later, in order to minimize springback and to nd out
lowing springback is smaller and the last bending radius
optimum shaping parameters, they combined nite ele-
is larger than the previous ones. [Rs > Rb] [3,17,18]
ments analysis and optimization techniques. The results
acquired from the study were compared with experimen-
tal data.
Tseng et al. [9] studied to examine copperberyllium Springback Rb

[CuBe] sheet metal behaviors in all principles. Tseng after bending Rs

and others researched on the importance of springback


value in shaping of CuNiBe alloy and have suggested s
many analytical formulas regarding estimated spring- Bending Force Has Not
back and performed designing of elements achieved b Removed Yet
by means of a computer [10]. Pourboghrat and Chand-
orkaran Chandorkar, Micari and others conducted a Fig. 1. Springback formed following bending.
Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258 253

Springback varies according to:

Minute
10
59
49
32

59
7
 Thickness of the material
 Material and process parameters [temperature, etc.]

Degree
 Type of material [elasticity modulus, yield stress,

2
1
1
1
1
0
Springback
deformation hardening, etc.]
 Period when punch load stays on the material

Degree
2.17
1.98
1.82
1.54
1.11
0.50
 Dimensions of die
 Force applied

Minute
As well as

10
59
49
32

35
7
 If R/T is big, springback increases accordingly

Degree
 Larger die gap results in more springback

106
121
136
151
165
92
 Springback varies proportionally with bending radius

Average
 As long as bending radius increases, springback

Degree
92.17
109.98
121.92
136.54
151.11
165.50
Bending angles of steel sheet metal 0.5 mm thickness, measurements performed on samples, arithmetical averages and springback amounts
increases as well [35,17,18]

92.16
107.05
121.55
136.50
151.32
165.59
In order to make bending at a desired angle, spring-
back amounts should be avoided. The following are
the methods that have been employed widely to avoid

92.14
106.59
121.49
136.22
151.00
166.03
springback:

 Bending angle is increased depending on springback

Method 1. Result of the experiment where thickness of the sheet metal is considered and the punch is kept 20 s.
92.10
106.55
121.50
138.19
151.24
165.52
 Bending area is crushed so as to not resile

Steel sheet metal sheet metal material with 0.5 mm thickness, samples
Material is stretched and later bent
 Period during which loads apply on material is

92.04
106.59
121.48
136.24
151.18
165.35
increased [35,17,18]

In order to accomplish bending at the desired angle, 92.15


107.05
121.58
138.41
150.56
165.40
bending angle is increased as much as springback. This
is also called excess bending. Excess bending signi-
cantly decreases springback. This may be arranged for
92.12
107.00
121.55
136.45
150.54
air bending by adjusting epact of the punch. Air-bend- 168.00
ing processes performed in V type bending dies, ex-
107.02
121.40
136.42
150.55
165.43
92.08

cess bending method, have been exercised in order to


prevent springback.
Although it has been told that this method may avoid
92.06
106.55
121.46
136.30
151.27
165.14

springback amount, accomplishing an ecient result


cannot be possible, thus certain negative points of this
method have been brought forward. Bending angle var-
106.58
121.48
136.07
151.02
165.17
92.13
92.00
106.45
121.00
136.00
150.30
155.10

Punch
Measured angle

Waste part (its thickness


105
120
135
160
165
90

is equal to sheet metal


thickness)
Bending angle

Female die
Table 1

90
75
60
45
30
15

Fig. 2. Parts of the modular die.


254 Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258

ies according to material types. As an example: spring- however using graphics derived from experiments for
back for soft steel, aluminum, copper, and brass can dierent materials is widely used, it has been found
be of any value between 0 and 1. This value varies be- out that in the literature such graphics are available
tween 12 and 15 for hard material. Since these gures for limited materials. Needs arising due to such lack
are approximate gures, it is impossible to acquire an have been constituted as basic motive of this study.
exact result. However, should springback be known ex-
actly, by making die suciently large, the desired bend-
ing can be achieved. 3. Materials and methods
Since force-compress stress will increase with meth-
ods using squeezing bending area between the punch Knowing or estimating springback value by perform-
and the matrix, springback will be eliminated. However, ing a series of experiments has been the basis of this
these types of bending processes require great forces, study. In order to perform the experiment, a simple
further stroke length of press machine should be very - and modular V type die as shown in the gure has
nely adjusted, otherwise damage both to die and part been designed. Although the die is simple, it has a mod-
may occur. If stroke length of press machine cannot ular structure in order to perform dierent processes by
be nely adjusted, longer stroke length shall result in employing small alterations. With these experiments,
cracks in the die and crushes in bending areas of bent springback graphics of STEEL SHEET METAL sheet
piece. It is taken to be under consideration that squeez- metal, with 20 25 mm dimensions and 0.5 mm thick-
ing weakens bending as well as the part and when con- ness, that was bent with linearly increased angles have
sidering that desired real arc may not be accomplished been derived. The experiments include bending opera-
in the material due to squeezing, one cannot say that this tions under [15, 30, 45, 60, 75, 90] angles in turn.
method is reliable. Further damages to die will increase These sheet metal materials were bent by a hydraulic
the cost as well. press bench where the time and forcing compress pres-
Keeping the punch longer on the matrix notwith- sure can be adjusted and each part that was bent was
standing decrease in springback, since it extends time, measured precisely by means of a prole meter with
increase in cost may be in question. 1 in. precision and optical angle measurement device.
After checking the literatures importance, the actual- Thus, it was tried to minimize mistakes in measurement.
ity of the subject has been brought forward. By evaluat- Spectrometric analysis of sheet metals was made and re-
ing all methods included in the literature one by one, it is sults were shown with formed graphics. Measurement
obvious that the simplest solution lies in increasing results of the bent parts were evaluated in computer
bending angle depending on springback. In this respect, and by using Microsoft Excel program springback

Material Name : DKP Springback


Angle
Chemical Composition : C 0,0539-S 0,0115- Ni 0,0138- Mn 0,35-
Cr 0,0151- Remainder Fe Bending Measured
Angle Angle
Sheet Thickness : T = 0,5 mm
Obtained
Bending Force : 1500N Angle

5
1.Method
4,5
2.Method
Springback Angles (Degree)

4 3.Method
3,5 4.Method
3
2,5
2
1,5
1
0,5
0
15 30 45 60 75 90
Bendind Angles (Degree)

Fig. 3. Graphic where four methods are combined (bending angles/springback angles).
Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258 255

Minute
graphics of sheet metals with dierent thicknesses were
obtained. While determining die dimensions, experimen-

56
47
30
59
44
21
tal formulas and acceptances were stipulated. Changing
these measurements and bending conditions may change

Degree
accomplished results. While using the formed tables and

2
2
2
1
1
1
Springback
graphics, care should be taken in conformity to bending

Degree
conditions and exercised experiments.

2.94
2.78
2.50
1.98
1.73
1.35
CNC wire erosion machine is specically used in the
manufacturing of modular die parts. Modular die parts

Minute
used in experiments were cut in CNC wire erosion bench
under determined bent angles with 1 l precision. Sur-

56
47
30
59
44
21
Method 2. Result of the experiment where thickness of the sheet metal is considered and the punch was immediately released after contact on the materials.
face precision of the die was accomplished by using 16

Degree
lm and 0.25 mm cutting wire, forming a one-pieced

107
122
136
151
166
92
punch as shown in Fig. 2 and both female die and male
punch were yielded. Since all calculated values were

Average
Degree
loaded into the computer, as they were values like op

92.94
107.78
122.50
136.98
151.73
166.35
Bending angles of steel sheet metal 0.5 mm thickness, measurements performed on samples, arithmetical averages and springback amounts
corner radius of the die, die curve, punch radius, etc.,
were made in exact dimension and one l precision.

93.15
108.05
122.50
137.05
152.10
166.50
While conducting experiments, four dierent test sets
and primarily bottom bending technique were used.

92.58
107.45
122.02
136.58
152.05
166.20
 In the rst series of experiments, punch was not
allowed to sit compressed to the bottom of the die.
A gap equal to the material thickness is left in

92.55
107.35
122.00
135.56
152.03
166.24
between the bottom of the die and the punch, so

Steel sheet metal sheet metal material with 0.5 mm thickness, samples
squeezing of sheet metal to avoid springback was pre-
vented. In the rst series of experiments, the punch

92.50
107.59
122.34
136.55
151.30
165.25
was kept on the sheet metal for 20 s, then the load
on the material was released by returning the punch.
 In the second series of experiments, again a gap equal 93.05
107.55
122.35
137.02
151.28
166.38
to the material thickness is left in between the bottom
of the die and this time the punch was not waited on
92.41
107.50
122.40
136.55
151.48
166.04
the material. As soon as the punch was lowered to the
last point, the load was relieved by returning the
punch.
93.10
107.39
122.40
137.00
151.45
166.12

 In the third series of experiments, the punch was low-


ered compressed to sit on the bottom of the die. This
means that the thickness of the sheet metal material
93.05
107.34
122.46
137.05
151.27
166.21

between the die and the punch was omitted. This time
the punch load was kept on the material for 20 s.
 In the fourth series of experiments, again the sheet
92.48
107.56
122.44
136.57
151.45
166.25

metal thickness was omitted, and punch was touched


to the bottom of the die, but this time the punch was
not waited on the material.
92.40
107.25
122.00
136.50
151.25
166.00

Experiments were carried out in ideal laboratory


Measured angle

medium. Adverse conditions [like dust, heat, etc.], which


may aect experiment results, were removed. Test parts
were grinded to be freed from burrs and cold bending
was exercised. Finally, no measurement with greater
105
120
135
160
165
90

than one minute default was met.


The results of the experiment were loaded into the
Bending angle

computer and by using Microsoft Excel program tables


and graphics were formed. The greatest and smallest
Table 2

values indicated the greatest deviation in calculation


90
75
60
45
30
15

of Arithmetical average (columns shaded with dark


256 Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258

color in Table 1 were omitted). The Arithmetic average 4. Results of experiments and discussion
of remaining eight values in degree and degree-min-
ute can be calculated. Also simulations curve of each It has been known that springback aects dimension
graphic is derived. Out of the ve dierent simulation and forms tolerances [1,2,10]. Dimensions and formed
curve methods, linear, logarithmic, power, exponential tolerances are very important in Industry, specically
and polynomial, it has been found out that the best in spare parts industry, tolerances are very important
that suits is polynomial curve seen in Fig. 4. Obtaining to produce spare parts. Therefore, the common point
small variation proves that results of experiments suit of the studies that have been performed on springback
to be used. At the bottom right corner of each graphic, is based on pre-estimation of springback amount and
variation amount and springback equation can be requirement in die design as to consider the springback
found. value.

Materials Name : DKP Springback


Chemical Composition : C 0,0539- S 0, 0115-Ni 0,0138- Angle

Mn 0,350-Cr 0,0151-Remainder Fe Bending Measured


Angle Angle
Sheet Thicknees : T=0,5 mm
Obtained
Bending Force : 1500 N Angle

2,50
Springback Angles (Degree)

2,00

1,50

1,00

0,50
y = -0,0002x2 + 0,0433x + 0,001
R2 = 0,9976
0,00
0,00 15,00 30,00 45,00 60,00 75,00 90,00 105,00
Bending Angles (Degree)

Fig. 4. Springback graphic of 0.5 mm steel sheet metal yielded by using the rst method and yielded polynomial curve equation.

Material Name : DKP Springback


Angle
Chemical Composition : C 0,0539-S 0,0115- Ni 0,0138-
Mn 0,35- Cr 0,0151-Remainder Fe Bending Measured
Angle Angle
Sheet Thickness : T = 0,5 mm
Obtained
Bending Force : 1500 N Angle

3,50

3,00
Springback Angles (Degree)

2,50

2,00

1,50

1,00

0,50
y = -8E-05x2 + 0,0303x + 0,888
R2 = 0,9876
0,00
0,00 15,00 30,00 45,00 60,00 75,00 90,00 105,00
Bending Angles (Degree)

Fig. 5. Springback graphic of 0.5 mm steel sheet metal yielded by using the second method and yielded polynomial curve equation.
Ozgur Tekaslan et al. / Materials and Design 27 (2006) 251258 257

Later results obtained from fourth series of experi-  From the values yielded from the table, keeping the
ments were compared with Fig. 3. While the results ob- punch load on sheet metal material for 20 s brings
tained from rst two series of experiments were usable in on an average 13 decrease in respect of material
nature, confusing results were obtained in the last two and bending angle.
series of experiments where thickness of sheet metal  Nevertheless, it has been observed that there occurred
material between the die and the punch was omitted. important dierences at positions where the punch
In this study, results obtained by using four dierent sits fully inside the die. There occurred a 4 dierence
methods, for 0.5 mm steel sheet metal, are introduced on between the results yielded by omitting the sheet
the same graphic in Fig. 3. metal thickness and making the punch sit on the bot-
When considering springback, the dimensions of die, tom of the die, and such results were yielded by con-
bending angle and the depth where the punch is com- sidering sheet metal thickness.
pressed to, in particular, are very important. In the third  In experiments where the sheet metal thicknesses were
and fourth series of experiments, punch depth has not omitted, uniform distribution cannot be observed.
been considered. Accordingly, it was noticed that Further, with experiments performed by omitting
crushes were occurred on the bending sections of the sheet metal thickness, smaller springback compared
material squeezed between the punch and the matrix, to the other two methods has been yielded. This
or die. Crushes on the bending areas restrict us to deter- results from crushing of sheet metal in a certain
mine springback precisely. As it can be observed from degree inside the die by the punch [thus, it brings
the graphics in Fig. 3, crushing amount in each angle forth a permanent change in shape].
diers from each other.  In the third experiment, the punch was lowered com-
From these results, the results of the rst method that pressed to sit on the bottom of the die. This means
are practicable are presented in Table 1 and second that thickness of sheet metal material between the
method in Table 2. Separate graphics of rst and second die and the punch was omitted. This time the punch
methods are presented in Figs. 4 and 5. load was kept on the material for 20 s. In the fourth
In these graphics, where combined results are pre- set of experiments, again sheet metal thickness was
sented, dierences of the four dierent methods can be omitted, and punch was touched to the bottom of
seen. Tables and graphics are constituted for all tested the die, but this time the punch was not waited on
materials. the material. It has been seen that the third and
The yielded graphics and tables are very easy to use. fourth methods are not suitable to determine spring-
From the tables, the values show to what extent can the back. It is known that springback is dependent on
tested material resile in various angles, in degree-min- material and process parameters. With the third and
utes. From the graphics, it is possible to nd springback fourth methods, sucient conditions to calculate
values for the tested angles. Further, nding corre- springback are not formed.
sponding values for mid values and such angles over
the tested value is very simple.
Finally, the user can nd springback value by using
tables, through drawing on the graphics or calculating
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