By the application of the three-point metal forming process, copious shapes can be formed. While doing the forming process, various unavoidable sheet metal defects will occur. This paper predominantly emphasizes springback and roughness defects and investigates the effects of these parameters with terpolymer Acrylonitrile Butadiene Styrene (ABS) fiber tool punch. Low-cost tooling and quality part development benefit from fiber tool punch over traditional steel tool punch. The springback and surface roughness are analyzed in the AA6061 sheet using steel and fiber punch in three-point U-bending operations, which are carried out as per ASTM standards. For this purpose, steel and fiber punch with nose diameters of 4, 8, and 12 mm and sheet metals of thicknesses 1 and 2 mm are used. The 8%–10% reduction in springback is achieved in fiber punch than steel punch. Also, the fiber punch offers 10%–47%better surface roughness than the steel punch. As the diameter of the punch increases, the roughness value also increases irrespective of the punch material. The fiber – reinforced ABS punch presents an attractive opportunity to reduce the springback effect and improve the surface quality of the finished product.
GuptaMSReddyDR. Design and analysis of aircraft sheet metal for spring back effect. Mater Today Proc2017; 4: 8287–8295.
3.
DaviesRWGrantGJKhaleelMA, et al. Forming-limit diagrams of aluminum tailor-welded blank weld material. Metallurgical Mater Trans A2001; 32: 275–283.
4.
DaviesRWOliverHESmithMT, et al. Characterizing Al tailor-welded blanks for automotive applications. JOM1999; 51: 46–50.
5.
BasakSPrasadKSMehtoA, et al. Parameter optimization and texture evolution in single point incremental sheet forming process. Proc IMechE, Part B: J Engineering Manufacture2020; 234: 126–139.
6.
GohilAModiB. Review of the effect of process parameters on performance measures in the incremental sheet forming process. Proc IMechE, Part B: J Engineering Manufacture2021; 235: 303–332.
7.
RagaiILazimDNemesJA. Anisotropy and springback in draw-bending of stainless steel 410: experimental and numerical study. J Mater Process Technol2005; 166: 116–127.
8.
GaoSHeTLiQ, et al. Research on springback characteristic in flexible multi-points 3D stretch-bending process. Proc IMechE, Part B: J Engineering Manufacture2022; 236: 440–452.
9.
TekınerZ. An experimental study on the examination of springback of sheet metals with several thicknesses and properties in bending dies. J Mater Process Technol2004; 145: 109–117.
10.
LiuTWangYWuJ, et al. Minimum bending radius of Al-Li alloy extrusions in stretch bending. Proc IMechE, Part B: J Engineering Manufacture2018; 232: 281–295.
11.
JiangH-JDaiH-L. A novel model to predict U-bending springback and time-dependent springback for a HSLA steel plate. Int J Adv Manuf Technol2015; 81: 1055–1066.
12.
YangXChoiCSeverNK, et al. Prediction of springback in air-bending of advanced high strength steel (DP780) considering young’s modulus variation and with a piecewise hardening function. Int J Mech Sci2016; 105: 266–272.
13.
ZhangDCuiZRuanX, et al. An analytical model for predicting springback and side wall curl of sheet after U-bending. Comput Mater Sci2007; 38: 707–715.
14.
Le QuilliecGBreitkopfPRoelandtJ-M, et al. Semi-analytical approach for plane strain sheet metal forming using a bending-under-tension numerical model. Int J Mater Forming2014; 7: 221–232.
15.
LeeM-GKimDWagonerRH, et al. Semi-analytic hybrid method to predict springback in the 2D draw bend test. J Appl Mech2007; 74: 1264–1275.
16.
SrinivasanRVasudevanDPadmanabhanP. Influence of friction parameters on springback and bend force in air bending of electrogalvanised steel sheet: an experimental study. J Braz Soc Mech Sci Eng2014; 36: 371–376.
17.
ThiruvarudchelvanS. Elastomers in metal forming: a review. J Mater Process Technol1993; 39: 55–82.
18.
RamkumarTSelvakumarMMohanrajM, et al. Microstructure and corrosion behavior of ZnO-Mg coating on AISI 4140 steel fabricated by spray coating. J Mater Eng Perform2020; 29: 5796–5806.
19.
BayoumiLSAttiaAS. Determination of the forming tool load in plastic shaping of a round tube into a square tubular section. J Mater Process Technol2009; 209: 1835–1842.
20.
KathalingamRNeelakandanBKrishnanE, et al. Comparison of incremental sheet metal forming process using newly designed multipoint tool with the existing single point tool by optimization and characterization methods on austenite stainless steel 202. Proc IMechE, Part B: J Engineering Manufacture2021; 235: 1298–1308.
21.
ElghawailAMPhamDTHuangJ, et al. Measurement of forces on multi-point forming tools using fibre Bragg grating sensors. Proc IMechE, Part B: J Engineering Manufacture2020; 234: 453–462.
22.
RamezaniMRipinZMAhmadR. Numerical simulation of sheet stamping process using flexible punch. Proc IMechE, Part B: J Engineering Manufacture2009; 223: 829–840.
23.
SalaG. A numerical and experimental approach to optimise sheet stamping technologies: part II — aluminium alloys rubber-forming. Mater Des2001; 22: 299–315.
24.
LeeJWKwonHCRheeMH, et al. Determination of forming limit of a structural aluminum tube in rubber pad bending. J Mater Process Technol2003; 140: 487–493.
25.
QuadriniFSantoLSqueoEA. Flexible forming of thin aluminum alloy sheets. Int J Modern Manuf Technols2010; 2: 79–84.
26.
ChenLChenHGuoW, et al. Experimental and simulation studies of springback in rubber forming using aluminium sheet straight flanging process. Mater Des2014; 54: 354–360.
27.
HwangY-MAltanT. Finite element analysis of tube hydroforming processes in a rectangular die. Finite Elem Anal Des2003; 39: 1071–1082.
28.
LiuHSXingZWBaoJ, et al. Investigation of the hot-stamping process for advanced high-strength steel sheet by numerical simulation. J Mater Eng Perform2010; 19: 325–334.
29.
ZhangMTianX. Residual stresses and strains analysis in press-braking bending parts considering multi-step forming effect. Proc IMechE, Part B: J Engineering Manufacture2020; 234: 788–800.
30.
Josue da SilvaPAlvaresAJ. Investigation of tool wear in single point incremental sheet forming. Proc IMechE, Part B: J Engineering Manufacture2020; 234: 170–188.
31.
TaherkhaniABastiANariman-ZadehN, et al. Achieving maximum dimensional accuracy and surface quality at the shortest possible time in single-point incremental forming via multi-objective optimization. Proc IMechE, Part B: J Engineering Manufacture2019; 233: 900–913.
32.
TrzepiecińskiT. Recent developments and trends in sheet metal forming. Metals2020; 10: 779.
33.
RamezaniMRipinZM. Effect of friction models on stress distribution of sheet materials during V-bending process. World Acad Sci Eng Technol2009; 32: 654–659.
34.
ChoudhuryIAGhomiV. Springback reduction of aluminum sheet in V-bending dies. Proc IMechE, Part B: J Engineering Manufacture2014; 228: 917–926.
35.
MickalichMKWennerML. Calculation of springback and its variation in channel forming operations. SAE Trans1988: 358–366.
36.
ThompsonNEEllenCH. A simple theory for “side-wall curl”. J Appl Metalworking1985; 4: 39–42.
37.
YuanBWangZ. A multi-deformable bodies solution method coupling finite element with meshless method in sheet metal flexible-die forming. Procedia Eng2017; 207: 1641–1646.
38.
Aluminum 6061-T6; 6061-T651. MatWeb, Source for Materials Information.
39.
CardenWDGengLMMatlockDK, et al. Measurement of springback. Int J Mech Sci2002; 44: 79–101.
40.
JamliMRFaridNM. The sustainability of neural network applications within finite element analysis in sheet metal forming: a review. Measurement2019; 138: 446–460.
41.
MaNZOgawaTLiuR, et al. Development of 3D Thick Shell and its Application to Sheet Metal Forming Simulation. In: Proceedings of the 10th international conference and workshop on numerical simulation of 3d sheet metal forming processes, Numisheet, Bristol, 4–9 September2016, pp.5–6.
42.
OsmanMShazlyMEl-MokaddemA, et al. Springback prediction in V-die bending: modelling and experimentation. J Achiev Mat Manuf Eng2010; 38: 179–186.
43.
ShisodeMPHazratiJMishraT, et al. Modeling mixed lubrication friction for sheet metal forming applications. Procedia Manuf2020; 47: 586–590.
44.
EvinETomášM. Verification of friction models implemented in the simulation software. Mat Sci Forum2020;994: 223–231.
45.
LöfgrenHB. A first order friction model for lubricated sheet metal forming. Theor Appl Mech Lett2018; 8: 57–61.
46.
FigueiredoLRamalhoAOliveiraMC, et al. Experimental study of friction in sheet metal forming. Wear2011; 271: 1651–1657.
47.
WangWZhaoYWangZ, et al. A study on variable friction model in sheet metal forming with advanced high strength steels. Tribol Int2016; 93: 17–28.
48.
JaworskiJTrzepiecińskiT. Research on durability of turning tools made of low-alloy high-speed steels. Kovove Mater2016; 54: 17–25.
49.
KirkhornLBushlyaVAnderssonM, et al. The influence of tool steel microstructure on friction in sheet metal forming. Wear2013; 302: 1268–1278.
50.
SulaimanMHFarahanaRNBienkK, et al. Effects of DLC/TiAlN-coated die on friction and wear in sheet-metal forming under dry and oil-lubricated conditions: Experimental and numerical studies. Wear2019; 438-439: 203040.
51.
HanSS. The influence of tool geometry on friction behavior in sheet metal forming. J Mater Process Technol1997; 63: 129–133.
52.
WangP-YWangZ-JXiangN, et al. Investigation on changing loading path in sheet metal forming by applying a property-adjustable flexible-die. J Manuf Process2020; 53: 364–375.
53.
WangZGuRChenS, et al. Effect of upper-die temperature on the formability of AZ31B magnesium alloy sheet in stamping. J Mater Process Technol2018; 257: 180–190.
54.
KowalikMTrzepiecińskiT. Examination of the influence of pressing parameters on strength and geometry of joint between aluminum plate and sheet metal. Arch Civil Mech Eng2012; 12: 292–298.
55.
SeshacharyuluKBandhaviCNaikBB, et al. Understanding friction in sheet metal forming-A review. Mater Today Proc2018; 5: 18238–18244.
56.
WangCMaRZhaoJ, et al. Calculation method and experimental study of coulomb friction coefficient in sheet metal forming. J Manuf Process2017; 27: 126–137.
57.
FleglerFNeuhäuserSGrocheP. Influence of sheet metal texture on the adhesive wear and friction behaviour of EN AW-5083 aluminum under dry and starved lubrication. Tribol Int2020; 141: 105956.
58.
MakhkamovAWagreDBaptistaAM, et al. Tribology testing to friction determination in sheet metal forming processes. Ciência Tecnologia dos Materiais2017; 29: e249–e253.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
