Finite Element Analysis of Sheet Metal Airbending Using Hyperform LS-DYNA
Air bending is one of the important metal forming
processes, because of its simplicity and large field application.
Accuracy of analytical and empirical models reported for the analysis
of bending processes is governed by simplifying assumption and do
not consider the effect of dynamic parameters. Number of researches
is reported on the finite element analysis (FEA) of V-bending, Ubending,
and air V-bending processes. FEA of bending is found to be
very sensitive to many physical and numerical parameters. FE
models must be computationally efficient for practical use. Reported
work shows the 3D FEA of air bending process using Hyperform LSDYNA
and its comparison with, published 3D FEA results of air
bending in Ansys LS-DYNA and experimental results. Observing the
planer symmetry and based on the assumption of plane strain
condition, air bending problem was modeled in 2D with symmetric
boundary condition in width. Stress-strain results of 2D FEA were
compared with 3D FEA results and experiments. Simplification of
air bending problem from 3D to 2D resulted into tremendous
reduction in the solution time with only marginal effect on stressstrain
results. FE model simplification by studying the problem
symmetry is more efficient and practical approach for solution of
more complex large dimensions slow forming processes.
[1] G. Martin and S. Tsang, "The Plastic Bending of beams Considering Die
Friction Effects," Transaction of ASME, J. Eng. Ind., pp. 237-250,
August 1966.
[2] Chuan to Wang, Gary Kinzel and Taylan Altan, "Mathematical
modeling of plane-strain bending of sheets and plates," J. Mater.
Process. Technol., vol. 39, pp 279-304, 1993.
[3] L. J. de Vin, A. H. Streppel, U. P. Singh and H. J. J. Kals, "A process
model for air bending," J. Mater. Process. Technol., vol. 57, pp. 48-54,
1996.
[4] Daw-Kwei Leu, "A simplified Approach for Evaluating Bendability and
Springback in Plastic Bending of Anisotropic Sheet Metals," J. Mater.
Process. Technol., vol. 66, pp. 9-17, 1997.
[5] P. P. Date, K. Narasimhan, S. K. Maiti and U. P. Singh, "On the
prediction of spring back in Vee- Bending of metallic sheets under plane
strain condition," Sheet Metal, Sept 1999, pp 447-456.
[6] Jenn-Terng Gau and Gary L. Kinzel, "An Experimental Investigation of
the Influence of the Bauschinger Effect on Springback Predictions," J.
Mater. Process. Technol., vol. 108, pp. 369-375, 2001.
[7] M. V. Inamdar, P. P. Date, K. Narsimhan, S. K. Maiti and U. P. Singh, "
Development of Artifitial Neural Network to predict springback in air V
bending," J. adv. Manuf. Technol., vol. 16, pp. 376-381, 2000.
[8] H. K. Raval, "Experimental & Theoretical Investigation of Bending
Process, (Vee & Three Roller bending)," PhD dissertation, South
Gujarat University, India, 2002.
[9] A. H. Gandhi, G. J. Solanki and H. K. Raval, "Investigation on Multiple
Pass Bending-A Simulation Study," Proc. Int. Conf. on Recent
Advances in Mechanical & Materials Engg., Kuala Lumpur, Malaysia,
30-31 May 2005, pp 971-976.
[10] A. H. Gandhi, G. J. Solanki and H. K. Raval, "On the effect of various
parameters on springback and energy in multiple pass (Air vee) bending:
part 1," Proc. 3rd Int. conf. on manuf. Research (ICMR2005), Cranfield
University, UK, 6-8 Sept 2005.
[11] Xuechun Li, Yuying Yang, Yongzhi Wang, Jun Bao and Shunping Li,
"Effect of Material Hardening Mode on the Springback Simulation
Accuracy of V-free Bending," J. Mater. Process. Technol., vol. 123, pp.
209-211, 2002.
[12] Albert Satorres, "Bending simulation of High strength steel by finite
elements", Master-s thesis, University of Oulu, 2005. Available:
http://www.oulu.fi/elme/ELME2/PDF/Diplomityot/Masters_Thesis_Alb
ert_Satorres%20.pdf.
[13] Trevor Dutton, "Review of Sheet Metal Forming Simulation Progress to
Date, Future Developments," 8th Int. LS-DYNA Users Conf., 2006.
[14] Peter Gantner and Herbert Bauer, "FEA Simulation of Bending
Processes with LS-DYNA," 8th Int. LS-DYNA Users Conf., 2006.
[15] Rahul K. Verma and A. Haldar, "Effect of Normal Anisotropy on
Springback," J. Mater. Process. Technol., to be published.
doi:10.1016/j.jmatprotec.2007.02.033.
[16] Duncan J. L., "The Mechanics of Sheet Metal Forming," Edward Arnold
Ltd., London, 1992.
[17] LS-DYNA Keyword Users Manual, Version 970, Livermore Software
Technology Corporation (LSTC), April 2003.
[1] G. Martin and S. Tsang, "The Plastic Bending of beams Considering Die
Friction Effects," Transaction of ASME, J. Eng. Ind., pp. 237-250,
August 1966.
[2] Chuan to Wang, Gary Kinzel and Taylan Altan, "Mathematical
modeling of plane-strain bending of sheets and plates," J. Mater.
Process. Technol., vol. 39, pp 279-304, 1993.
[3] L. J. de Vin, A. H. Streppel, U. P. Singh and H. J. J. Kals, "A process
model for air bending," J. Mater. Process. Technol., vol. 57, pp. 48-54,
1996.
[4] Daw-Kwei Leu, "A simplified Approach for Evaluating Bendability and
Springback in Plastic Bending of Anisotropic Sheet Metals," J. Mater.
Process. Technol., vol. 66, pp. 9-17, 1997.
[5] P. P. Date, K. Narasimhan, S. K. Maiti and U. P. Singh, "On the
prediction of spring back in Vee- Bending of metallic sheets under plane
strain condition," Sheet Metal, Sept 1999, pp 447-456.
[6] Jenn-Terng Gau and Gary L. Kinzel, "An Experimental Investigation of
the Influence of the Bauschinger Effect on Springback Predictions," J.
Mater. Process. Technol., vol. 108, pp. 369-375, 2001.
[7] M. V. Inamdar, P. P. Date, K. Narsimhan, S. K. Maiti and U. P. Singh, "
Development of Artifitial Neural Network to predict springback in air V
bending," J. adv. Manuf. Technol., vol. 16, pp. 376-381, 2000.
[8] H. K. Raval, "Experimental & Theoretical Investigation of Bending
Process, (Vee & Three Roller bending)," PhD dissertation, South
Gujarat University, India, 2002.
[9] A. H. Gandhi, G. J. Solanki and H. K. Raval, "Investigation on Multiple
Pass Bending-A Simulation Study," Proc. Int. Conf. on Recent
Advances in Mechanical & Materials Engg., Kuala Lumpur, Malaysia,
30-31 May 2005, pp 971-976.
[10] A. H. Gandhi, G. J. Solanki and H. K. Raval, "On the effect of various
parameters on springback and energy in multiple pass (Air vee) bending:
part 1," Proc. 3rd Int. conf. on manuf. Research (ICMR2005), Cranfield
University, UK, 6-8 Sept 2005.
[11] Xuechun Li, Yuying Yang, Yongzhi Wang, Jun Bao and Shunping Li,
"Effect of Material Hardening Mode on the Springback Simulation
Accuracy of V-free Bending," J. Mater. Process. Technol., vol. 123, pp.
209-211, 2002.
[12] Albert Satorres, "Bending simulation of High strength steel by finite
elements", Master-s thesis, University of Oulu, 2005. Available:
http://www.oulu.fi/elme/ELME2/PDF/Diplomityot/Masters_Thesis_Alb
ert_Satorres%20.pdf.
[13] Trevor Dutton, "Review of Sheet Metal Forming Simulation Progress to
Date, Future Developments," 8th Int. LS-DYNA Users Conf., 2006.
[14] Peter Gantner and Herbert Bauer, "FEA Simulation of Bending
Processes with LS-DYNA," 8th Int. LS-DYNA Users Conf., 2006.
[15] Rahul K. Verma and A. Haldar, "Effect of Normal Anisotropy on
Springback," J. Mater. Process. Technol., to be published.
doi:10.1016/j.jmatprotec.2007.02.033.
[16] Duncan J. L., "The Mechanics of Sheet Metal Forming," Edward Arnold
Ltd., London, 1992.
[17] LS-DYNA Keyword Users Manual, Version 970, Livermore Software
Technology Corporation (LSTC), April 2003.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:51462", author = "Himanshu V. Gajjar and Anish H. Gandhi and Harit K. Raval", title = "Finite Element Analysis of Sheet Metal Airbending Using Hyperform LS-DYNA", abstract = "Air bending is one of the important metal forming
processes, because of its simplicity and large field application.
Accuracy of analytical and empirical models reported for the analysis
of bending processes is governed by simplifying assumption and do
not consider the effect of dynamic parameters. Number of researches
is reported on the finite element analysis (FEA) of V-bending, Ubending,
and air V-bending processes. FEA of bending is found to be
very sensitive to many physical and numerical parameters. FE
models must be computationally efficient for practical use. Reported
work shows the 3D FEA of air bending process using Hyperform LSDYNA
and its comparison with, published 3D FEA results of air
bending in Ansys LS-DYNA and experimental results. Observing the
planer symmetry and based on the assumption of plane strain
condition, air bending problem was modeled in 2D with symmetric
boundary condition in width. Stress-strain results of 2D FEA were
compared with 3D FEA results and experiments. Simplification of
air bending problem from 3D to 2D resulted into tremendous
reduction in the solution time with only marginal effect on stressstrain
results. FE model simplification by studying the problem
symmetry is more efficient and practical approach for solution of
more complex large dimensions slow forming processes.", keywords = "Air V-bending, Finite element analysis, HyperformLS-DYNA, Planner symmetry.", volume = "1", number = "8", pages = "384-6", }