Optimization of Process Parameters Affecting on Spring-Back in V-Bending Process for High Strength Low Alloy Steel HSLA 420 Using FEA (HyperForm) and Taguchi Technique

In this study, process parameters like punch angle, die opening, grain direction, and pre-bend condition of the strip for deep draw of high strength low alloy steel HSLA 420 are investigated. The finite element method (FEM) in association with the Taguchi and the analysis of variance (ANOVA) techniques are carried out to investigate the degree of importance of process parameters in V-bending process for HSLA 420&ST12 grade material. From results, it is observed that punch angle had a major influence on the spring-back. Die opening also showed very significant role on spring back. On the other hand, it is revealed that grain direction had the least impact on spring back; however, if strip from flat sheet is taken, then it is less prone to spring back as compared to the strip from sheet metal coil. HyperForm software is used for FEM simulation and experiments are designed using Taguchi method. Percentage contribution of the parameters is obtained through the ANOVA techniques.

Springback Simulations of Monolithic and Layered Steels Used for Pressure Equipment

Carbon steel is used in boilers, pressure vessels, heat exchangers, piping, structural elements and other moderatetemperature service systems in which good strength and ductility are desired. ASME Boiler and Pressure Vessel Code, Section II Part A (2004) provides specifications of ferrous materials for construction of pressure equipment, covering wide range of mechanical properties including high strength materials for power plants application. However, increased level of springback is one of the major problems in fabricating components of high strength steel using bending. Presented work discuss the springback simulations for five different steels (i.e. SA-36, SA-299, SA-515 grade 70, SA-612 and SA-724 grade B) using finite element analysis of air V-bending. Analytical springback simulations of hypothetical layered materials are presented. Result shows that; (i) combination of the material property parameters controls the springback, (ii) layer of the high ductility steel on the high strength steel greatly suppresses the springback.

Effect of Friction Models on Stress Distribution of Sheet Materials during V-Bending Process

In a metal forming process, the friction between the material and the tools influences the process by modifying the stress distribution of the workpiece. This frictional behaviour is often taken into account by using a constant coefficient of friction in the finite element simulations of sheet metal forming processes. However, friction coefficient varies in time and space with many parameters. The Stribeck friction model is investigated in this study to predict springback behaviour of AA6061-T4 sheets during V-bending process. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The plane-strain bending process is simulated in ABAQUS/Standard. We compared the computed punch load-stroke curves and springback related to the constant coefficient of friction with the defined friction model. The results clearly showed that the new friction model provides better agreement between experiments and results of numerical simulations. The influence of friction models on stress distribution in the workpiece is also studied numerically

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.